TM 5-3800-205-23-1 Part 1 Model 613CS and Model 613CWD

TM 5-3800-205-23-1
FIELD MAINTENANCE MANUAL

(INCLUDES UNIT AND DIRECT SUPPORT MAINTENANCE)
FOR
SCRAPER, TRACTOR
ELEVATING, SELF-PROPELLED, 11 CUBIC YARDS, SECTIONALIZED
MODEL 613CS
(NSN 3805-01-497-0697) (EIC: EE4)
AND
DISTRIBUTOR, WATER, TANK TYPE,

2525 GALLON CAPACITY, SECTIONALIZED
MODEL 613CWD
(NSN 3825-01-497-0690) (EIC: EEF)
TRACTOR AND COMMON COMPONENTS
Approved for public release; distribution is unlimited.
HEADQUARTERS, DEPARTMENT OF THE ARMY
JULY 2005
only Left Blank.
This page is blank.

TM 5-3800-205-23-1
WARNING SUMMARY
This warning summary contains general safety warnings and hazardous materials warnings that must be understood and
applied during operation and maintenance of this equipment. Failure to observe these precautions could result in serious injury
or death to personnel. Also included are explanations of safety and hazardous materials icons used within the technical man-
ual.
BIOLOGICAL - abstract symbol bug shows that a material may contain bacteria or viruses that
present a danger to life or health.
CHEMICAL - drops of liquid on hand shows that the material will cause burns or irritation to
human skin or tissue.
EAR PROTECTION - Headphones over ears show that noise level will harm ears.
ELECTRICAL - electrical wire to arm with electricity symbol running through human body shows
that shock hazard is present.
EYE PROTECTION - person with goggles shows that the material will injure the eyes.
FIRE - flame shows that a material may ignite and cause burns.
FLYING PARTICLES - arrows bouncing off face with face shield shows that particles flying
through the air will harm face.
HEAVY PARTS - hand with heavy object on top shows that heavy parts can crush and harm.
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TM 5-3800-205-23-1
HEAVY OBJECT - human figure stopping over heavy object shows physical injury potential from
improper lifting technique..
HEAVY PARTS - heavy object on human figure shows that heavy parts present a danger to life or
limb.
HOT AREA - hand over object radiating heat shows that part is hot and can burn.
HYDRAULIC FLUID PRESSURE - hydraulic fluid spraying human figure shows that fluid escap-
ing under great pressure can cause injury or death.
POISON - skull and crossbones shows material is poinsonous or is a danger to life.
RADIOACTIVE - identifies a material that emits radioactive energy and can injure human tissue or
organs.
VAPOR - human figure in a cloud shows that material vapors present a danger to life or health.
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TM 5-3800-205-23-1
FOR INFORMATION ON FIRST AID, REFER TO FM 4-25.11.
WARNING
CARBON MONOXIDE (EXHAUST GASES) CAN KILL!

• Carbon monoxide is a colorless, odorless, deadly poison which, when breathed, deprives the body of oxygen
and causes suffocation. Exposure to air containing carbon monoxide produces symptoms of headache, dizzi-
ness, loss of muscular control, apparent drowsiness, and coma. Permanent brain damage or death can result
from severe exposure.
• Carbon monoxide occurs in exhaust fumes of internal combustion engines. Carbon monoxide can become dan-
gerously concentrated under conditions of inadequate ventilation. The following precautions must be observed
to ensure safety of personnel when engine of tractor is operated.
1. DO NOT operate tractor engine in enclosed areas.
2. DO NOT idle tractor engine without adequate ventilation.
3. DO NOT drive tractor with inspection plates or cover plates removed.
4. BE ALERT for exhaust poisoning symptoms. They are:
• Headache
• Dizziness
• Sleepiness
• Loss of muscular control
5. If you see another person with exhaust poisoning symptoms:
• Remove person from area.
• Expose to fresh air.
• Keep person warm.
• Do not permit physical exercise.
• Administer cardiopulmonary resuscitation (CPR), if necessary.
• Notify a medic.
6. BE AWARE. The field protective mask for nuclear-biological-chemical (NBC) protection will not protect you from car-
bon monoxide poisoning.
The Best Defense Against Carbon Monoxide Poisoning Is Good Ventilation!
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TM 5-3800-205-23-1
WARNING
BATTERIES
• To avoid injury, eye protection and acid-resistant gloves must be worn when working around batteries. Do not
smoke, use open flame, make sparks or create other ignition sources around batteries. If a battery is giving off
gases, it can explode and cause injury to personnel. Remove all jewelry such as rings, ID tags, watches, and
bracelets. If jewelry or a tool contacts a battery terminal, a direct short will result in instant heating, damage to
equipment, and injury to personnel.
• Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolyte makes contact
with skin, eyes or clothing, take immediate action to stop the corrosive burning effects. Failure to follow these
procedures may result in death or serious injury to personnel.
a. Eyes. Flush with cold water for no less than 15 minutes and seek medical attention immediately.
b. Skin. Flush with large amounts of cold water until all acid is removed. Seek medical attention as required.
c. Internal. If corrosion or electrolyte is ingested, drink large amounts of water or milk. Follow with milk of magnesia,
beaten egg or vegetable oil. Seek medical attention immediately.
d. Clothing/Equipment. Wash area with large amounts of cold water. Neutralize acid with baking soda or household
ammonia.
WARNING
COMPRESSED AIR
Compressed air used for cleaning or drying purposes, or for clearing restrictions, should never exceed 30 psi
(207 kPa). Use protective equipment and exercise caution to avoid injury to personnel.
WARNING
ETHER COLD START SYSTEM

Ether fuel is extremely flammable and toxic. DO NOT smoke and make sure you are in a well-ventilated
area away from heat, open flames or sparks. Wear eye protection. Avoid contact with skin and eyes and
avoid breathing ether fumes. If fluid enters or fumes irritate the eyes, wash immediately with large quantities
of clean water for 15 minutes. Seek medical attention immediately if ether is inhaled or causes eye irritation.
Failure to follow this warning may cause death or serious injury to personnel.
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TM 5-3800-205-23-1
WARNING
FUEL HANDLING
• DO NOT smoke or permit any open flame in area of machine while you are servicing fuel system. Be sure hose
nozzle is grounded against filler tube during refueling to prevent static electricity. Failure to follow this warn-
ing may result in injury to personnel or equipment damage.
• DO NOT perform fuel system checks, inspections or maintenance while smoking or near fire, flames or sparks.
Fuel may ignite, causing damage to machine and injury or death to personnel.
• Operating personnel must wear fuel-resistant gloves when handling fuels. If exposed to fuel, promptly wash
exposed skin and change fuel-soaked clothing. Failure to follow this warning may result in injury to personnel.
WARNING
HAZARDOUS WASTE DISPOSAL

When servicing this machine, performing maintenance, or disposing of materials such as engine coolant,
hydraulic fluid, lubricants, battery acids or batteries, and CARC paint, consult your unit/local hazardous
waste disposal center or safety office for local regulatory guidance. If further information is needed, please
contact The Army Environmental Hotline at 1-800-872-3845.
WARNING
HEARING PROTECTION
Hearing protection is required when operating machine or when within 23 feet of machine when it is operat-
ing. Failure to wear hearing protection may result in hearing loss.
WARNING
HYDRAULIC SYSTEM
• Do NOT disconnect or remove any hydraulic system line or fitting unless engine is shut down and hydraulic
system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid
under pressure can penetrate the skin, causing serious injury.
• At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic
lines. Failure to do so could result in injury.
WARNING
ISU-60 CONTAINER
Never transport container with doors open. Transporting container with doors open may cause serious injury
or death to personnel.
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TM 5-3800-205-23-1
WARNING
NBC EXPOSURE
• If NBC exposure is suspected, personnel wearing protective equipment should handle all air cleaner media.
Consult your NBC Officer or NBC NCO for appropriate handling or disposal procedures. Failure to follow this
warning may result in illness or death to personnel.
• NBC contaminated filters must be handled using adequate precautions (FM 21-40) and must be disposed of by
trained personnel. Failure to follow this warning may result in illness or death to personnel.
WARNING
IF NBC EXPOSURE IS SUSPECTED ALL AIR
FILTER MEDIA WILL BE HANDLED BY PER-
SONNEL WEARING FULL NBC PROTEC-
TIVE EQUIPMENT. SEE OPERATOR/
MAINTENANCE MANUAL.
7690-01-114-3702
To order this NBC decal use:

National Stock Number (NSN) - 7690-01-114-3702
Part Number (PN) - 12296626
Commercial and Government Entity Code (CAGEC) - 19207
WARNING
NON-POTABLE WATER
(WATER DISTRIBUTOR)
NEVER drink water contained in water distributor tank. Water contained or dispensed from tank is NON-
POTABLE. Drinking non-potable water could result in illness or death.
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TM 5-3800-205-23-1
WARNING
OPERATION SAFETY
• Use caution and maintain three-point contact at all times when mounting and dismounting machine, to avoid
injury to personnel.
• DO NOT allow riders on the tractor. Failure to follow this warning may result in serious injury or death to per-
sonnel.
• DO NOT operate machine unless seat belt has been fastened. Failure to follow this warning may result in seri-
ous injury or death, in the event of an accident.
• BE ALERT for personnel in the area while operating machine. Always check to ensure area is clear of person-
nel and obstructions before starting engine, moving machine or lowering or raising scraper bowl. Failure to fol-
low this warning may result in serious injury or death to personnel or damage to equipment.
• Never leave the operator’s position without applying the parking brake. Failure to follow this warning may
result in death to injury to personnel or damage to equipment.
• Never use starting fluid or spray to aid in starting the engine other than the on-board ether cold start system.
Failure to follow this warning may result in death or injury to personnel or damage to equipment.
• Always use a ground guide when driving machine up or down ramps in preparation for highway, marine or air
transport, or when driving tractor into position for assembly to scraper. Failure to use a ground guide may
result in an accident, causing death or injury to personnel or damage to equipment.
• When loaded and traveling across a hillside, reduce speed significantly BEFORE turning uphill. Failure to do
so may cause machine to roll over, resulting in injury or death to personnel.
• Do NOT operate machine if parking brake was applied due to a malfunction of airbrake system or parking
brake. Correct any problem before attempting to operate machine. Personal injury or death can result from a
brake malfunction.
• For water distributor only, DO NOT operate machine at speeds greater than 18 mph (29 kph), in all weather
and road conditions and fully loaded. Maximum operating at 18 mph (29 kph) is 7 hours within a 24-hour
period. Failure to follow this warning may cause external or internal injury due to excessive whole-body vibra-
tion.
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TM 5-3800-205-23-1
WARNING
PREPARATION FOR TRANSPORT
• Use extreme caution when handling heavy parts. Provide adequate support and use assistance during proce-
dure. Ensure that any lifting device used is in good condition and of suitable lift capacity. Keep clear of heavy
parts supported only by lifting device. Failure to follow this warning may result in death or injury to personnel.
• If operating machine without ROPS/FOPS, drive with extreme caution, at low idle, and in 1st gear or reverse
ONLY. Machine has no rollover/falling object protection without ROPS/FOPS. Failure to follow this warning
may cause injury or death to personnel or damage to equipment.
• Always use a ground guide when moving machine during preparation for transport procedures (driving up and
down ramps, onto airdrop platform or onto rail flatcars). Failure to use a ground guide may result in an acci-
dent, causing death or injury to personnel or damage to equipment.
• Use extreme caution when driving sectionalized tractor with stability skids and no ROPS/FOPS. Use first gear
forward or reverse and low idle ONLY. Ground guide or ground safety officer assistance is required to monitor
path in front of front stability skid, to avoid obstacles and direct tractor operation. Failure to follow this warn-
ing may result in injury or death to personnel or damage to equipment.
• Use assistance and handle windshield with caution to ensure it does not become damaged. Failure to do so may
damage windshield or cause personnel injury from cut glass if windshield breaks.
• Use extreme caution when climbing on ladder. Failure to exercise caution may result in a fall, causing injury to
personnel.
• Removal of upper handrail on right side of tractor leaves right side of tractor without any means to safely climb
on machine. Use caution when climbing on right side if upper handrail has been removed. Failure to do so may
result in injury to personnel.
• Do NOT remove exhaust stack until it has cooled to the touch. Wear gloves and protective cloth-
ing as required to guard against burns. Failure to follow this warning may cause personnel
injury.
WARNING
PRESSURIZED AIR
• Do NOT disconnect any air system lines or fittings unless engine is shut down and air system pressure is
relieved. Failure to follow this warning could result in serious injury to personnel.
• Always wear eye protection when disconnecting air lines. Residual air will be expelled. Failure to follow this
warning may result in serious eye injury.
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TM 5-3800-205-23-1
WARNING
PRESSURIZED COOLING SYSTEM

• DO NOT service cooling system unless engine has been allowed to cool down. This is a pressurized cooling
system and escaping steam or hot coolant will cause serious burns.
• DO NOT remove cooling system radiator cap when engine is hot. Allow engine to cool down. Failure to follow
this warning may cause serious burns.
• Wear effective eye, glove, and skin protection when handling coolants. Failure to do so may cause injury.
WARNING
SLAVE STARTING
When slave starting tractor:
• Use NATO slave cable that does NOT have loose or missing insulation.
• DO NOT proceed if suitable cable is not available.
• DO NOT use civilian-type jumper cables.
• DO NOT allow disabled and booster machines to come in contact with each other at any time during slave
starting
Failure to follow this warning may result in injury or death to personnel.
WARNING
SOLVENT CLEANING COMPOUND

Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low toxic material.
However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-ventilated
areas. Keep away from open flames and other sources of ignition. Failure to do so may result in injury or
death to personnel.
WARNING
TIRES
• Operating machine with underinflated or defective tire may lead to tire failure and loss of traction or control.
Damage to equipment or injury to personnel may result.
• Use a self-inflating chuck and stand at a distance behind tire when inflating tire. Failure to do so could result in
injury or death to personnel.
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TM 5-3800-205-23-1
WARNING
WORK SAFETY
• Lifting cables, chains, hooks, and slings used for lifting machine must be in good condition and of
suitable capacity. Failure to follow this warning may result in injury or death to personnel and
damage to equipment.
• Improper use of lifting equipment and improper attachment of cables to machine can result in seri-
ous personnel injury and equipment damage. Observe all standard rules of safety.
• Hitch and steering movement can reduce clearances suddenly and cause personnel injury. Always stop engine
BEFORE working in area of hitch link.
• Configuration changes to cutting edge and cutting edge-to-elevator clearance adjustments should NEVER be
attempted without first securing the bowl by blocking it so that it is firmly supported. Failure to follow this
warning may cause injury to personnel.
• Use extreme caution when handling heavy parts. Provide adequate support and use assistance dur-
ing procedure. Ensure that any lifting device used is in good condition and of suitable load capac-
ity. Keep clear of heavy parts supported only by lifting device. Failure to follow this warning may
result in death or injury to personnel.
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TM 5-3800-205-23-1
LIST OF EFFECTIVE PAGES/WORK PACKAGES
Date of issue for original manual is:
Original 15 JULY 2005
TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 64 AND TOTAL NUMBER OF WORK
PACKAGES IS 172 CONSISTING OF THE FOLLOWING:
Page/WP *Change
No. No.
Cover/(Back Blank) 0
a to h 0
A/(B Blank) 0
i to xii 0
WP 0001 00 to 0172 00 0
Index-1 to Index 8 0
* Zero in this column indicates an original page or work package.
A
TM 5-3800-205-23-1
This Page Intentionally Left Blank.
B
TM 5-3800-205-23-1
TECHNICAL MANUAL HEADQUARTERS

TM 5-3800-205-23-1 DEPARTMENT OF THE ARMY
Washington, D.C. 15 July 2005
FIELD MAINTENANCE MANUAL
(INCLUDES UNIT AND DIRECT SUPPORT MAINTENANCE)
FOR
SCRAPER, TRACTOR
ELEVATING, SELF-PROPELLED, 11 CUBIC YARDS, SECTIONALIZED
MODEL 613CS
(NSN 3805-01-497-0697) (EIC: EE4)
and
DISTRIBUTOR, WATER, TANK TYPE,

2525 GALLON CAPACITY, SECTIONALIZED
MODEL 613CWD
(NSN 3825-01-497-0690) (EIC: EEF)
TRACTOR and COMMON COMPONENTS
REPORTING ERRORS and RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any mistakes or if you know of a way to improve the pro-
cedures, please let us know. Submit your DA Form 2028 (Recommended Changes to Equipment Technical
Publications), through the Internet, on the Army Electronic Product Support (AEPS) website. The Internet
address is http://aeps.ria.army.mil. If you need a password, scroll down and click on “ACCESS REQUEST
FORM”. The DA Form 2028 is located in the ONLINE FORMS PROCESSING section of the AEPS. Fill
out the form and click on SUBMIT. Using this form on the AEPS will enable us to respond quicker to your
comments and better manage the DA Form 2028 program. You may also mail, fax or e-mail your letter, DA
Form 2028 direct to: AMSTA-LC-CI/TECH PUBS, TACOM-RI, 1 Rock Island Arsenal, Rock Island, IL
61299-7630. The e-mail address is: TACOM-TECH-PUBS@ria.army.mil. The fax number is DSN 793-
0726 or Commercial (309) 782-0726.
Table of Contents
Page
Number
VOLUME 1 - TM 5-3800-205-23-1
Warning Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a
How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
CHAPTER 1 INTRODUCTORY INFORMATION WITH THEORY OF OPERATION
WP 0001 00 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1

WP 0002 00 Equipment Description and Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00-1
WP 0003 00 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003 00-1
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TM 5-3800-205-23-1
Table of Contents - Continued

Page
Number
CHAPTER 2 TROUBLESHOOTING PROCEDURES
WP 0004 00 Troubleshooting Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-1

WP 0005 00 Tests, Inspections, and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-1
WP 0006 00 Troubleshooting Symptom Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-1
WP 0007 00 Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-1
CHAPTER 3 UNIT MAINTENANCE PROCEDURES
WP 0008 00 Service Upon Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-1

WP 0009 00 Unit Preventive Maintenance Checks and Services (PMCS) Introduction . . . . 0009 00-1
WP 0010 00 Unit Preventive Maintenance Checks and Services (PMCS) . . . . . . . . . . . . . . 0010 00-1
CHAPTER 4 UNIT LEVEL TRACTOR MAINTENANCE
Engine
WP 0011 00 Rocker Arm Cover Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-1
WP 0012 00 Crankcase Breather Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-1
WP 0013 00 Engine Oil Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0013 00-1
WP 0014 00 Engine Oil Pan Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00-1
WP 0015 00 Engine Oil Sampling Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0015 00-1
Fuel System
WP 0016 00 Fuel Lines and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00-1
WP 0017 00 Fuel Shutoff Solenoid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0017 00-1
WP 0018 00 Air Cleaner Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018 00-1
WP 0019 00 Air Intake Hose Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019 00-1
WP 0020 00 Fuel Governor Hoses and Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 0020 00-1
WP 0021 00 Secondary Fuel Filters and Base Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 0021 00-1
WP 0022 00 Ether Cold Start Aid System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022 00-1
WP 0023 00 Accelerator Pedal Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0023 00-1
WP 0024 00 Throttle Control Cable Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0024 00-1
Exhaust System
WP 0025 00 Exhaust Guard, Exhaust Pipe and Muffler Replacement . . . . . . . . . . . . . . . . . 0025 00-1
Cooling System
WP 0026 00 Hydraulic Oil Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0026 00-1
WP 0027 00 Radiator Hoses, Tubes, and Clamps Replacement . . . . . . . . . . . . . . . . . . . . . . 0027 00-1
WP 0028 00 Thermostat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0028 00-1
WP 0029 00 Water Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0029 00-1
WP 0030 00 Belt Tightener Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0030 00-1
WP 0031 00 Fan and Fan Drive Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0031 00-1
WP 0032 00 Fan, Alternator, and Water Pump Drive Belts Replacement. . . . . . . . . . . . . . . 0032 00-1
Electrical System
WP 0033 00 Electrical General Maintenance Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . 0033 00-1
WP 0034 00 Alternator Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0034 00-1
WP 0035 00 Starter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0035 00-1
WP 0036 00 Backup Alarm Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0036 00-1
WP 0037 00 Battery Disconnect Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0037 00-1
ii
TM 5-3800-205-23-1

Page
Number
Electrical System - Continued

WP 0038 00 Circuit Breakers Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0038 00-1
WP 0039 00 EMS Panel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0039 00-1
WP 0040 00 Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0040 00-1
WP 0041 00 Hazard Flasher Unit Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0041 00-1
WP 0042 00 Instrument Panel Gages and Bulbs Replacement . . . . . . . . . . . . . . . . . . . . . . . 0042 00-1
WP 0043 00 Key Start Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0043 00-1
WP 0044 00 Light Switch and Ground Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 0044 00-1
WP 0045 00 Main, Fuel Pump, Start, and Air Intake Heater Relays Replacement . . . . . . . 0045 00-1
WP 0046 00 Neutral Start Switches Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0046 00-1
WP 0047 00 Parking Brake and Emergency Brake Pressure Switches Replacement . . . . . . 0047 00-1
WP 0048 00 Relay Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0048 00-1
WP 0049 00 Rocker Switches Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0049 00-1
WP 0050 00 Parking Light/Blackout Marker Light Maintenance . . . . . . . . . . . . . . . . . . . . . 0050 00-1
WP 0051 00 Turn Signal/hazard Flasher Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . 0051 00-1
WP 0052 00 Blackout Drive Light Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0052 00-1
WP 0053 00 Dimmer Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0053 00-1
WP 0054 00 Headlights Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0054 00-1
WP 0055 00 EMS Alarm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0055 00-1
WP 0056 00 Air Intake Heater Timer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0056 00-1
WP 0057 00 Work Light Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0057 00-1
WP 0058 00 Stop Lamp Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0058 00-1
WP 0059 00 Torque Converter Temperature Switch Replacement . . . . . . . . . . . . . . . . . . . 0059 00-1
WP 0060 00 Torque Convertor Temperature Sender Replacement . . . . . . . . . . . . . . . . . . . . 0060 00-1
WP 0061 00 Coolant Temperature Sender Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0061 00-1
WP 0062 00 Engine and Transmission Speed Sensors Replacement . . . . . . . . . . . . . . . . . . 0062 00-1
WP 0063 00 EngineTemperature and Ether Start Aid Temperature Switch Replacement . . 0063 00-1
WP 0064 00 Engine Oil, Fuel Level Relay, and Ejector Detent Pressure
Switches Replacement 0064 00-1
WP 0065 00 Engine Fuel System Pressure Switch Replacement . . . . . . . . . . . . . . . . . . . . . 0065 00-1
WP 0066 00 Service Brake Air Supply Block Solenoid Valve Replacement . . . . . . . . . . . . 0066 00-1
WP 0067 00 Battery and Battery Cables Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0067 00-1
WP 0068 00 Slave Start Receptacle and Cables Replacement. . . . . . . . . . . . . . . . . . . . . . . . 0068 00-1
Transmission
WP 0069 00 Transmission Shift Control Cable Replacement . . . . . . . . . . . . . . . . . . . . . . . . 0069 00-1
WP 0070 00 Transmission Shift Control Cam and Linkage Replacement . . . . . . . . . . . . . . 0070 00-1
WP 0071 00 Transmission Shift Lever and Lock Replacement. . . . . . . . . . . . . . . . . . . . . . . 0071 00-1
WP 0072 00 Transmission Oil Filter and Oil Filter Base Replacement. . . . . . . . . . . . . . . . . 0072 00-1
WP 0073 00 Transmission Oil Sampling Valve Replacement. . . . . . . . . . . . . . . . . . . . . . . . 0073 00-1
WP 0074 00 Transmission Oil Cooler Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0074 00-1
Transfer Assembly
WP 0075 00 Transmission Oil Suction Screen and Tube Assembly
(Magnetic Screen) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0075 00-1
Propeller and Propeller Shafts
WP 0076 00 Lower Prop Shaft Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0076 00-1
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Page
Number
Front Axle
WP 0077 00 Final Drive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0077 00-1
WP 0078 00 Front Axle Shafts Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0078 00-1
WP 0079 00 Front Spindle Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0079 00-1
WP 0080 00 Front Wheel, Hub, Brake Disc, and Wheel Bearings and Seals Maintenance . 0080 00-1
WP 0081 00 Differential Lock Control Valve Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 0081 00-1
Brake System
WP 0082 00 Parking Brake Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0082 00-1
WP 0083 00 Air Compressor Governor and Air Compressor Maintenance . . . . . . . . . . . . . 0083 00-1
WP 0084 00 Front Service Brakeshoes Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0084 00-1
WP 0085 00 Skid Steer Control and Air Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . 0085 00-1
WP 0086 00 Air/Hydraulic Brake Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0086 00-1
WP 0087 00 Brake Caliper Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0087 00-1
WP 0088 00 Parking Brake Actuator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0088 00-1
WP 0089 00 Parking Brake or Emergency Brake Control Valve Replacement . . . . . . . . . . 0089 00-1
WP 0090 00 Service Brake Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0090 00-1
WP 0091 00 Pressure Protection Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0091 00-1
WP 0092 00 Double Check Valves Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0092 00-1
WP 0093 00 Air Hoses and Tubes Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0093 00-1
WP 0094 00 Air Tanks Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0094 00-1
WP 0095 00 Service Brake Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0095 00-1
Wheels and Tires
WP 0096 00 Front Tire and Rim Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0096 00-1
Steering
WP 0097 00 Steering Wheel and Column Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0097 00-1
Body and Cab
WP 0098 00 ROPS/FOPS Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0098 00-1
WP 0099 00 Engine Grille, Engine Access Door, and Hood Assembly Replacement . . . . . 0099 00-1
WP 0100 00 Guard Plates Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0100 00-1
WP 0101 00 Fenders Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0101 00-1
WP 0102 00 Windshield Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0102 00-1
WP 0103 00 Seat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0103 00-1
WP 0104 00 Seat Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0104 00-1
WP 0105 00 Rifle Rack Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0105 00-1
WP 0106 00 Fire Extinguisher and Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0106 00-1
Body Accessory Items
WP 0107 00 Rearview and Side Mirrors Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0107 00-1
WP 0108 00 Data Plate and Decal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0108 00-1
WP 0109 00 Windshield Washer Reservoir and Pump Replacement . . . . . . . . . . . . . . . . . . 0109 00-1
WP 0110 00 Windshield Wiper Arm and Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . 0110 00-1
WP 0111 00 Air Horn Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0111 00-1
WP 0112 00 Air Horn Solenoid Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0112 00-1
WP 0113 00 Air Horn Switch Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0113 00-1
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Hydraulic System
WP 0114 00 Direction Control and Hydraulic Control Levers Replacement . . . . . . . . . . . . 0114 00-1
WP 0115 00 Hydraulic Oil Filters and Bypass Valve Maintenance . . . . . . . . . . . . . . . . . . . 0115 00-1
WP 0116 00 Hydraulic Lines and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0116 00-1
WP 0117 00 Hydraulic Oil Sampling Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0117 00-1
WP 0118 00 Hydraulic Tank Safety Relief Valve Assembly Maintenance. . . . . . . . . . . . . . 0118 00-1
WP 0119 00 Hydraulic Tank Sight Gage Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0119 00-1
WP 0120 00 Hydraulic Tank Filler Cap Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0120 00-1
WP 0121 00 Hydraulic Oil Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0121 00-1
CHAPTER 5 DIRECT SUPPORT LEVEL TRACTOR MAINTENANCE
Engine
WP 0122 00 Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0122 00-1
WP 0123 00 Front and Rear Engine Supports Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 0123 00-1
WP 0124 00 Engine Front and Rear Lifting Brackets Replacement . . . . . . . . . . . . . . . . . . . 0124 00-1
WP 0125 00 Cylinder Head Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0125 00-1
WP 0126 00 Vibration Damper and Pulley Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0126 00-1
WP 0127 00 Crankshaft Front Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0127 00-1
WP 0128 00 Crankshaft Rear Seal Carrier Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0128 00-1
WP 0129 00 Crankshaft Rear Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0129 00-1
WP 0130 00 Flywheel Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0130 00-1
WP 0131 00 Flywheel Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0131 00-1
WP 0132 00 Engine Front Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0132 00-1
WP 0133 00 Rocker Shaft Group Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0133 00-1
WP 0134 00 Engine Oil Filter Base and Oil Cooler Maintenance. . . . . . . . . . . . . . . . . . . . . 0134 00-1
WP 0135 00 Engine Oil Pump Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0135 00-1
WP 0136 00 Exhaust Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0136 00-1
WP 0137 00 Intake Manifold Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0137 00-1
Fuel System
WP 0138 00 Fuel Injector Control Linkage Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0138 00-1
WP 0139 00 Fuel Unit Injector Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0139 00-1
WP 0140 00 Injector Synchronization, Fuel Setting, and Fuel Timing . . . . . . . . . . . . . . . . . 0140 00-1
WP 0141 00 Fuel Transfer Pump and Governor Replacement . . . . . . . . . . . . . . . . . . . . . . . 0141 00-1
WP 0142 00 Aftercooler and Air Inlet Heater Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 0142 00-1
WP 0143 00 Turbocharger Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0143 00-1
Cooling System
WP 0144 00 Radiator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0144 00-1
WP 0145 00 Fan Drive Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0145 00-1
Transmission/Transfer Assembly
WP 0146 00 Torque Converter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0146 00-1
WP 0147 00 Transmission/Transfer Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . 0147 00-1
WP 0148 00 Transmission Hydraulic Control Valve Replacement. . . . . . . . . . . . . . . . . . . . 0148 00-1
WP 0149 00 Transmission Oil and Scavenger Pump Replacement. . . . . . . . . . . . . . . . . . . . 0149 00-1
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Number
Propeller and Propeller Shafts

WP 0150 00 Upper Prop Shaft Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0150 00-1
Front Axle
WP 0151 00 Front Axle Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0151 00-1
WP 0152 00 Differential and Bevel Gear Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0152 00-1
Steering
WP 0153 00 Steering Hydraulic Cylinders Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0153 00-1
WP 0154 00 Steering Hydraulic Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . 0154 00-1
Frame, Towing, and Articulation Systems
WP 0155 00 Draft Frame, Hitch, and Tractor Frame Pins and Bearings Replacement . . . . . 0155 00-1
WP 0156 00 Steering Link Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0156 00-1
Body and Cab
WP 0157 00 Windshield Glass Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0157 00-1
Hydraulic System
WP 0158 00 Hydraulic and Steering Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0158 00-1
WP 0159 00 Elevator/Water Hydraulic Pump Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 0159 00-1
WP 0160 00 Main Control Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0160 00-1
WP 0161 00 Elevator/Water Pump Control Valve Replacement. . . . . . . . . . . . . . . . . . . . . . 0161 00-1
WP 0162 00 Hydraulic Tank Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0162 00-1
CHAPTER 6 COMPONENTS OF END ITEM (COEI) MAINTENANCE
WP 0163 00 Container Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0163 00-1

WP 0164 00 Container Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0164 00-1
WP 0165 00 Cutting Edge Wheels and Load Transfer Axles Repair . . . . . . . . . . . . . . . . . . 0165 00-1
WP 0166 00 Load Transfer Relief Valve and Hose Assembly Repair . . . . . . . . . . . . . . . . . 0166 00-1
WP 0167 00 Auxiliary Fuel Tank Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0167 00-1
CHAPTER 7 SUPPORTING INFORMATION
WP 0168 00 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0168 00-1

WP 0169 00 Maintenance Allocation Chart (MAC) Introduction . . . . . . . . . . . . . . . . . . . . . 0169 00-1
WP 0170 00 Maintenance Allocation Chart (MAC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0170 00-1
WP 0171 00 Expendable and Durable Items List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0171 00-1
WP 0172 00 Tool Identification List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0172 00-1
WP 0173 00 Torque Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0173 00-1
WP 0174 00 Preparation for Storage or Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0174 00-1
WP 0175 00 List of Principle Caterpillar Dealers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0175 00-1
WP 0176 00 Nuclear, Biological, and Chemical (NBC) and ElectroMagnetic Pulse
(EMP) Susceptible Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0176 00-1
WP 0177 00 Warranty Information (Caterpillar, Inc.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0177 00-1
WP 0178 00 Warranty Information (All Except Caterpillar, Inc.). . . . . . . . . . . . . . . . . . . . . 0178 00-1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1
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Page
Number
VOLUME 2 - TM 5-3800-205-23-2
CHAPTER 1 UNIT LEVEL SCRAPER MAINTENANCE
Fuel System
WP 0001 00 Fuel Pump, Hoses, and Tubes Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1
WP 0002 00 Fuel/Water Separator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00-1
Electrical System
WP 0004 00 Ground Straps Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-1
WP 0005 00 Composite Light Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-1
WP 0006 00 Blackout Light Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-1
WP 0007 00 Fuel Level Sending Unit and Dial Sensor Replacement . . . . . . . . . . . . . . . . . 0007 00-1
WP 0008 00 Backup Alarm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-1
Axles
WP 0009 00 Rear Hub and Disc Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0009 00-1
Brake System
WP 0010 00 Air/Hydraulic Brake Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-1
WP 0011 00 Rear Service Brakeshoes and Caliper Replacement . . . . . . . . . . . . . . . . . . . . . 0011 00-1
WP 0012 00 Air Hoses and Tubes Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0012 00-1
WP 0013 00 Quick-Release Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0013 00-1
WP 0014 00 Brake Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00-1
WP 0015 00 Service Brakes Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0015 00-1
Wheel and Tire
WP 0016 00 Rear Tire and Rim Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00-1
Body and Cab
WP 0017 00 Toolbox and Rear Deck Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0017 00-1
Body and Accessory Items
WP 0018 00 Data Plate Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0018 00-1
Hydraulic System
WP 0019 00 Elevator Motor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019 00-1
WP 0020 00 Hydraulic Lines and Fittings Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020 00-1
WP 0021 00 Check Valve and Lift Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0021 00-1
Scraper System
WP 0022 00 Elevator Assembly Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0022 00-1
WP 0023 00 Elevator Flights and Chains Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0023 00-1
WP 0024 00 Elevator Guard Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0024 00-1
WP 0025 00 Elevator Chain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0025 00-1
WP 0026 00 Elevator Chain Idler Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0026 00-1
WP 0027 00 Ejector Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0027 00-1
WP 0028 00 Cutting Edges and Router Bits Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0028 00-1
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Number
CHAPTER 2 DIRECT SUPPORT LEVEL SCRAPER MAINTENANCE
Axles
WP 0029 00 Rear Wheel Bearings and Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0029 00-1
Hydraulic System
WP 0030 00 Floor Check Valve Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0030 00-1
WP 0031 00 Ejector Cylinder Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0031 00-1
WP 0032 00 Floor Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0032 00-1
Scraper System
WP 0033 00 Elevator Assembly Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0033 00-1
WP 0034 00 Elevator Chain Idler Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0034 00-1
WP 0035 00 Elevator Chain Roller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0035 00-1
WP 0036 00 Elevator Drive Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0036 00-1
WP 0037 00 Ejector Carrier Roller Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0037 00-1
WP 0038 00 Ejector Guide Roller Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0038 00-1
WP 0039 00 Ejector Support Roller Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0039 00-1
WP 0040 00 Sliding Floor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0040 00-1
WP 0041 00 Sliding Floor Roller Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0041 00-1
WP 0042 00 Sliding Floor Link Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0042 00-1
WP 0043 00 Sliding Floor Dump Arm Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0043 00-1
WP 0044 00 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0044 00-1

WP 0049 00 Torque Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0049 00-1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index -1
viii
TM 5-3800-205-23-1

Page
Number
VOLUME 3 - TM 5-3800-205-23-3
CHAPTER 1 UNIT LEVEL WATER DISTRIBUTOR MAINTENANCE
Fuel System
WP 0001 00 Fuel Pump, Hoses, and Tubes Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1
WP 0002 00 Fuel/Water Separator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0002 00-1
Electrical System
WP 0004 00 Composite Light Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-1
WP 0005 00 Blackout Light Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0005 00-1
WP 0006 00 Work Light Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0006 00-1
Electrical System - Continued
WP 0007 00 Fuel Level Sending Unit and Dial Sensor Replacement . . . . . . . . . . . . . . . . . 0007 00-1
WP 0008 00 Backup Alarm Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-1
WP 0009 00 Water Tank Wiring Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0009 00-1
Axles
WP 0010 00 Rear Hub and Disc Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0010 00-1
Brake System
WP 0011 00 Air/hydraulic Brake Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0011 00-1
WP 0012 00 Rear Service Brakeshoes and Brake Caliper Replacement . . . . . . . . . . . . . . . . 0012 00-1
WP 0013 00 Air Hose and Tube Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0013 00-1
WP 0014 00 Quick-Release Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0014 00-1
WP 0015 00 Brake Lines Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0015 00-1
WP 0016 00 Service Brakes Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0016 00-1
Wheel and Tire
WP 0017 00 Rear Tire and Rim Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0017 00-1
Body and Cab
WP 0018 00 Rear Handrails and Step Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . 0018 00-1
WP 0019 00 Toolbox Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0019 00-1
WP 0020 00 Water Tank Inspection Cover Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0020 00-1
WP 0021 00 Water Tank Access Cover Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0021 00-1
WP 0022 00 Mudflap and Rear Grabhandle Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0022 00-1
Body Accessory Items
WP 0023 00 Data Plate Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0023 00-1
Hydraulic System
WP 0024 00 Hydraulic Hoses Maintenance (Draft Arm-to-Water Tank) . . . . . . . . . . . . . . . 0024 00-1
WP 0025 00 Hydraulic Hoses Replacement (Water Tank-to-Hydraulic Motor) . . . . . . . . . . 0025 00-1
WP 0026 00 Check Valve and Lift Cylinder Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0026 00-1
ix
TM 5-3800-205-23-1

Page
Number
Water Distributor System

WP 0027 00 Butterfly Valve Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0027 00-1
WP 0028 00 Upper and Lower Spray Bar Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0028 00-1
WP 0029 00 Control Panel and Air Hoses Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0029 00-1
WP 0030 00 Hose Reel Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0030 00-1
WP 0031 00 Water Level Sender Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0031 00-1
WP 0032 00 Water Tank Foot Valve Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . 0032 00-1
WP 0033 00 Suction Inlet Manual Valve and Vacuum Valve Replacement . . . . . . . . . . . . . 0033 00-1
WP 0034 00 Suction Hose Foot Valve Assembly Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . 0034 00-1
WP 0035 00 Water Hose Assemblies, Inlet/Outlet Pipes, and Manifolds Replacement . . . . 0035 00-1
CHAPTER 2 DIRECT SUPPORT LEVEL WATER DISTRIBUTOR MAINTENANCE
Axles
WP 0036 00 Rear Wheel Bearings and Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 0036 00-1
Hydraulic System
WP 0037 00 Water Pump Hydraulic Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 0037 00-1
Water Distributor System
WP 0038 00 Water Pump Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0038 00-1
WP 0039 00 Water Pump Housing Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0039 00-1
WP 0040 00 Water Pump Check Valve Assembly Maintenance. . . . . . . . . . . . . . . . . . . . . . 0040 00-1
WP 0041 00 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0041 00-1

WP 0046 00 Torque Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0046 00-1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1
x
TM 5-3800-205-23-1
HOW TO USE THIS MANUAL
INTRODUCTION
1. This manual is designed to help you perform troubleshooting and maintenance on the 613CS Scraper and the 613CWD
Water Distributor.
2. This manual is divided into volumes and written in work package format:
a. Volume 1 addresses tractor/common components and procedures. Volume 2 addresses scraper unique components.
Volume 3 addresses water distributor unique components.
b. Chapters divide the manual into major categories of information (e.g., Introductory Information with Theory of
Operation, Troubleshooting Procedures, Unit Maintenance Procedures, Unit Level Tractor Maintenance, Direct
Support Level Tractor Maintenance, Components of End Item (COEI) Maintenance, Unit Level Scraper Mainte-
nance, Direct Support Level Scraper Maintenance, Unit Level Water Distributor Maintenance, Direct Support
Level Water Distributor Maintenance, and Supporting Information).
c. Each chapter is divided into work packages, which are identified by a 6-digit number (e.g., 0001 00, 0002 00, etc.)
located on the upper right-hand corner of each page. The work package page number (e.g., 0001 00-1, 0001 00-2,
etc.) is located centered at the bottom of each page.
d. If a Change Package is issued to this manual, added work packages use the 5th and 6th digits of their number to
indicate new material. For instance, work packages inserted between WP 0001 00 and WP 0002 00 are numbered
WP 0001 01, WP 0001 02, etc.
3. Scan through this manual to become familiar with its organization and contents before attempting to operate or maintain
the equipment.
CONTENTS OF VOLUME 1 OF THIS MANUAL
1. A Warning Summary is located at the beginning of this manual. Become familiar with these warnings before operating or
performing maintenance on the scraper or water distributor.
2. A Table of Contents, located in the front of this manual, lists all chapters and work packages in the publication.
a. The Table of Contents also provides Reporting Errors and Recommending Improvements information and DA
Form 2028 addresses, for the submittal of corrections to this manual.
b. If you cannot find what you are looking for in the Table of Contents, refer to the alphabetical Index at the back of
this manual.
3. Chapter 1, Introductory Information with Theory of Operation, provides general information on the equipment.
4. Chapter 2, Troubleshooting Procedures, contains a Troubleshooting Symptom Index. If the machine malfunctions, this
index should always be consulted to locate the appropriate troubleshooting procedure.
5. Chapter 3, Unit Maintenance Procedures, contains Service Upon Receipt and PMCS.
6. Chapter 4, Unit Level Tractor Maintenance, provides instructions on Unit level maintenance tractor components.
7. Chapter 5, Direct Support Level Tractor Maintenance, provides instructions on DS level maintenance of the tractor.
8. Chapter 6, Components of End Item (COEI) Maintenance, contains maintenance of the components of end item.
9. Chapter 7 includes Supporting Information: References; Maintenance Allocation Chart (MAC) Introduction, Mainte-
nance Allocation Chart (MAC); Expendable and Durable Items List; Tool Identification List; Torque Limits Preparation
for Storage or Shipment; List of Principal Caterpillar Dealer; and NBC and EMP Susceptible Components.
FEATURES OF THIS MANUAL
1. WARNINGs, CAUTIONs, NOTEs, subject headings, and other important information are highlighted in BOLD print as a
visual aid.
xi
TM 5-3800-205-23-1
WARNING
A WARNING indicates a hazard which may result in death or serious injury.
CAUTION
A CAUTION is a reminder of safety practices or directs attention to usage practices that may result in dam-
age to equipment.
NOTE
A NOTE is a statement containing information that will make the procedures easier to perform.
2. Statements and words of particular interest may be printed in CAPITAL LETTERS to create emphasis.
3. Within a procedural step, reference may be made to another work package in this manual or to another manual. These ref-
erences indicate where you should look for more complete information.
If you are told: “Remove Rocker Arm Cover (WP 0011 00)”, go to Work Package 0011 00 in this manual for instruc-
tions on replacing the rocker arm covers.
4. Illustrations are placed after, and as close to, the procedural steps to which they apply. Callouts placed on the art may be
text or numbers, or both; whichever method is easier for the soldier.
5. Numbers located at lower right corner of art (e.g. 390-001; 390-002, etc.) are art control numbers and are used for tracking
purposes. Disregard these numbers.
6. Dashed leader lines used in the Lubrication Chart in WP 0010 00 (PMCS Introduction) indicate that called out lubrication
points are located on both sides of the machine.
7. Technical instructions include metric units as well as standard units. For your reference, a Metric Conversion Chart is
located on the inside back cover of this manual.
NOTE
If at any time you are unsure how to use this manual or you cannot locate the information you need, notify
your supervisor.
xii
TM 5-3800-205-23-1
CHAPTER 1
INTRODUCTORY INFORMATION WITH
THEORY OF OPERATION
TM 5-3800-205-23-1

TM 5-3800-205-23-1
GENERAL INFORMATION 0001 00
SCOPE
1. Type of Manual. This manual is for use in performing Field Maintenance (includes Unit and Direct Support Mainte-
nance) on the 613CS Scraper and 613CWD Water Distributor, components of the Airborne Scraper Water Distributor
System (ASWDS).
2. Equipment Name and Model Number.
a. Scraper, Tractor, Elevating, Self-Propelled, 11 Cubic Yards, Sectionalized, Model 613CS.
b. Distributor, Water, Tank Type, 2525 Gallon Capacity, Sectionalized, Model 613CWD.
3. Purpose of Equipment.
a. The 613CS Scraper is used to self-load, haul, dump, and spread soil in worldwide earthmoving and construction
projects by U.S. Army forces in engineer troop support.
b. The 613CWD Water Distributor provides dust control, soil stabilization, and power washing capabilities in world-
wide earthmoving and construction projects by U.S. Army forces in engineer troop support.
MAINTENANCE FORMS, RECORDS, AND REPORTS
Department of the Army forms and procedures used for the equipment will be those prescribed by DA Pam 738-750,
Functional User’s Manual for the Army Maintenance Management System (TAMMS), as contained in the Maintenance Man-
agement Update.
REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIRS)
If your machine needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what
you don’t like about your equipment. Let us know why you don’t like the design or performance. Put it on an SF Form 368
(Product Quality Deficiency Report). Mail it to us at: Commander, U.S. Army Tank-automotive and Armaments Command,
ATTN: AMSTA-AC-NML, Rock Island, Illinois 61299-7630. We’ll send you a reply.
CORROSION PREVENTION AND CONTROL (CPC)
1. Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is important that any corrosion
problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the
problem in future items.
2. While corrosion is typically associated with rusting of metals, it can also include deterioration of other materials, such as
rubber and plastic. Unusual cracking, softening, swelling, or breaking of these materials may be a corrosion problem. If a
corrosion problem is identified, it can be reported using SF Form 368 (Product Quality Deficiency Report). Use of key
words such as “corrosion,” “rust,” “deterioration,” or “cracking” will ensure that the information is identified as a CPC
problem. The form should be submitted to the address specified in DA Pam 738-750.
THREAT OF NUCLEAR, BIOLOGICAL, AND CHEMICAL (NBC) CONTAMINATION
1. The 613C machine incorporates a CARC painted exterior. Materials used in the machine are metal, rubber, plastic, fabric,
and glass.
2. In the event of NBC contamination, decontaminants for these surfaces and materials are listed in FM 3-5. For decontami-
nation procedures, refer to FM 3-7 and to TM 5-3800-205-10-1 or TM 5-3800-205-10-2, Operation Under Unusual Con-
ditions.
3. For a list of 613C susceptible components, refer to WP 0176 00 in this manual.
0001 00-1
TM 5-3800-205-23-1
GENERAL INFORMATION - CONTINUED 0001 00
ELECTROMAGNETIC PULSE (EMP) EXPOSURE

1. Components listed and designated as EMP susceptible may be damaged by EMP exposure. If the machine is exposed to
an EMP incident, verify proper operation and repair as necessary.
2. For a list of 613C susceptible components, refer to WP 0176 00 in this manual.
OZONE DEPLETING SUBSTANCES

Listing to be provided by requiring activity.
DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE

For destruction of Army materiel to prevent enemy use, refer to TM 750-244-3.
PREPARATION FOR STORAGE OR SHIPMENT

For preparation for storage or shipment procedures, refer to WP 0174 00.
WARRANTY INFORMATION
The machines are warranted by Caterpillar Inc. in accordance with TM 5-3800-205-10-1 or TM 5-3800-205-10-2. War-
ranty starts on the date found in block 23, DA Form 2408-9 in the logbook. Report all defects in material or workmanship to
your supervisor, who will take appropriate action through your Unit Maintenance shop.
LIST OF ABBREVIATIONS/ACRONYMS
NOTE
Refer to ASME Y14.38-1999 for standard abbreviations.
ABBREVIATION/ACRONYMS DEFINITION
AAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional Authorization List
AAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Association of American Railroads
AOAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Army Oil Analysis Program
ASWDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Airborne Scraper Water Distributor System
BDC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bottom Dead Center
BFOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bridgestone/Firestone Off Road
BII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Basic Issue Items
C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centigrade or Celsius
CAGEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Commercial and Government Entity Code
CARB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . California Air Resources Board
CARC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chemical Agent Resistant Coating
CCA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cold Cranking Amps
CFR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Code of Federal Regulations
CID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cubic Inch Displacement
cm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centimeter
COEI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Components of End Item
CONUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Continental United States
CPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Corrosion Prevention and Control
0001 00-2
TM 5-3800-205-23-1
LIST OF ABBREVIATIONS/ACRONYMS - CONTINUED

DAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Decontamination Apparatus
ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Control Module
EIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Improvement Recommendations
EMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ElectroMagnetic Pulse
EMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Monitoring System
EPA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Environmental Protection Agency
F. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fahrenheit
FRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel-air Ration Control
ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feet
gal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gallons
GCWR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gross Combination Weight Rating
GET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ground Engaging Tools
GIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gabarit International de Chargement
gpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gallons per minute
GVWR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gross Vehicle Weight Rating
HAZMAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hazardous Material
IAW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .In Accordance With
ISO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .International Organization for Standardization
ISU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal Airlift/Helicopter Slingable Container Unit
kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilogram
km . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Kilometer
kPa. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilopascal
kph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kilometers per Hour
kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Kilowatt
in.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inches
l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liter
lb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pounds
lb-ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pound Foot
LC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Center
lph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liters per Hour
m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Meters
mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Millimeter
mph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Miles per hour
MSDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Material Safety Data Sheets
MTMC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Military Traffic Management Command
MTMCTEA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Military Traffic Management Command Transportation Engineering Agency
NATO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . North Atlantic Treaty Organization
NBC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nuclear, Biological, and Chemical
0001 00-3
TM 5-3800-205-23-1
LIST OF ABBREVIATIONS/ACRONYMS - CONTINUED

Nm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Newton Meter
NSN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .National Stock Number
OCONUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Outside Continental United States
OSHA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Occupational Safety and Health Administration
PMCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preventive Maintenance Checks and Services
Qty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Quantity
ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Report of Discrepancy
RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Revolutions per minute
ROPS/FOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rollover Protective Structure/Falling Object Protective Structure
RO/RO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Roll-On/Roll-Off
Rqd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Required
TAMMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Army Maintenance Management System
TMPH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ton-mile per-hour
U/M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Unit of Measure
V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Volts
yd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yards
END OF WORK PACKAGE
0001 00-4
TM 5-3800-205-23-1
EQUIPMENT DESCRIPTION AND DATA 0002 00
EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES (SCRAPER)

1. Characteristics.
a. The 613CS Scraper, used in conjunction with the 613CWD Water Distributor, provides the Army with the capabil-
ity to efficiently build roads, airstrips, and other engineering assets in a wide variety of geographic, environmental,
and tactical situations.
b. The scraper self-loads, hauls, dumps, and spreads earth, thereby providing grading capability from start to finish of
a job.
c. The machine is capable of all critical earthmoving operations in a degraded mode of operation (i.e., without ROPS/
FOPS).
2. Capabilities and Features.
NOTE
Refer to Equipment Data (Scraper) at the end of this work package for machine dimensions, weights, fluid
capacities, and other miscellaneous equipment data.
a. The scraper consists of two sections: front tractor section and rear elevating scraper section. These may be sepa-
rated (sectionalization) to allow external air transport by CH-47 helicopter.
b. All parts and tools needed for sectionalization are contained within an ISU-60 container. This container also has
stowage space for parts that are removed from the machine for sectionalization.
c. After sectionalization, the tractor half of this machine is reassembled with the scraper. The tractor may also be
assembled and operated with the water distributor half of the 613CWD Water Distributor (interchangeability).
d. The scraper can be transported by driving onto the following aircraft: C-17 and C-5. After reconfiguration, the
scraper can be driven onto a C-130 for transport.
e. The machine can be rigged on an air delivery platform for airdrop from C-130 aircraft.
f. Commercial trailers, trains or marine vessels can also transport the scraper.
g. The scraper can fresh-water ford to a depth of 3.28 ft (1 m) without damage or contamination of lubricants.
h. The tractor front section has the following capabilities and features:
(1) Caterpillar® 3116TA turbocharged diesel engine with six in-line cylinders, generating 175 horsepower @
2300 RPM;
(2) integral ether cold start for engine startup down to -25°F (-32°C);
(3) Caterpillar® powershift, manual transmission with six forward speeds and one reverse;
(4) operator’s cab with adjustable seat and steering column/wheel;
(5) removable bolt-on ROPS/FOPS canopy;
(6) front full-floating drive axle with outboard planetary final drives;
(7) differential lock control to reduce wheel slippage when high traction is required;
(8) articulated frame steering with two double-acting steering cylinders;
(9) oil sampling valves for engine, transmission, and hydraulic systems;
(10) NATO slave receptacle; and
(11) mounting provisions for M16 rifle and portable fire extinguisher inside cab, and decontamination appara-
tus at left front of tractor.
0002 00-1
TM 5-3800-205-23-1
EQUIPMENT DESCRIPTION AND DATA - CONTINUED 0002 00
EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES (SCRAPER) - CONTINUED

i. The scraper rear section has the following capabilities and features:
(1) non-drive axle;
(2) elevating bowl with a load rate of less than one minute, to an 11 yd3 (8.4 m3) capacity;
(3) interchangeable and reversible cutting edges, with center section predrilled to allow installation of four
cutting teeth;
(4) two-speed forward, one reverse speed elevator to lift material into bowl; and
(5) retracting floor and dozer-type ejector for rapid unloading.
j. When sectionalized, tractor can be driven using front and rear skids for stability, and steered using a skid steer sys-
tem.
EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES (WATER DISTRIBUTOR)
1. Characteristics.
a. The 613CWD Water Distributor, used in conjunction with the 613CS Scraper, provides the Army with the capabil-
ity to efficiently build roads, helipads, airfields, landing zones/airstrips, and other engineering assets in a wide vari-
ety of geographic, environmental, and tactical situations.
b. The water distributor self-loads, transports, and distributes a maximum of 2525 gallons (9,558 liters) of water, soil
stabilization or dust palliative solutions, providing soil stabilization, dust control, and compaction capabilities.
c. The machine also provides power washing and de-icing operations when required.
d. With optional attachments mounted, the machine provides soil cultivation and road grading capabilities.
e. The water distributor is capable of all critical water distribution operations in a degraded mode of operation (i.e.,
without ROPS/FOPS).
2. Capabilities and Features.
NOTE
Refer to Equipment Data (Water Distributor) at the end of this work package for machine dimensions,
weights, fluid capacities, and other miscellaneous equipment data.
a. The water distributor consists of two sections: front tractor section and rear water distributor section. These may be
separated (sectionalization) to allow external air transport by CH-47 helicopter.
b. All parts and tools needed for sectionalization are contained within an ISU-60 container. This container also has
stowage space for parts that are removed from the machine for sectionalization.
c. After sectionalization, the tractor half of this machine is reassembled with the water distributor half. It may also be
assembled and operated with the scraper half of the 613CS Scraper (interchangeability).
d. The water distributor can be transported by driving onto the following aircraft: C-17 and C-5. After reconfigura-
tion, it can be driven onto a C-130 for transport.
e. The machine can be rigged on an air delivery platform for airdrop from C-130 aircraft.
f. Commercial trailers, trains or marine vessels can also transport the water distributor.
g. The water distributor can fresh-water ford to a depth of 3.28 ft (1 m) without damage or contamination of lubri-
cants.
h. The tractor front section has the following capabilities and features:
(1) Caterpillar® 3116TA turbocharged diesel engine with six in-line cylinders, generating 175 horsepower @
2300 RPM;
(2) integral ether cold start for engine startup down to -25°F (-32°C);
0002 00-2
TM 5-3800-205-23-1
EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES (WATER DISTRIBUTOR) - CONTINUED
(3) Caterpillar® powershift, manual transmission with six forward speeds and one reverse;
(4) operator’s cab with adjustable seat and steering column/wheel;
(5) removable bolt-on ROPS/FOPS canopy;
(6) front full-floating drive axle with outboard planetary final drives;
(7) differential lock control to reduce wheel slippage when high traction is required;
(8) articulated frame steering with two double-acting steering cylinders;
(9) oil sampling valves for engine, transmission, and hydraulic systems;
(10) NATO slave receptacle; and
(11) mounting provisions for M16 rifle and portable fire extinguisher inside cab, and decontamination appara-
tus at left front of tractor.
i. The water distributor rear section has the following capabilities and features:
(1) non-drive axle;
(2) ASTM 588 (core ten) corrosion-resistant steel tank with a maximum capacity of 2525 gallons (9558
liters);
(3) internal, positive prime foot valve at bottom of tank;
(4) interior surge baffling to ensure stability on side slopes;
(5) 20-inch access cover (with bag cutter/can breaker) at rear of tank provides access for top loading and for
adding soil stabilization, dust control or deicing compounds to tank;
(6) 20-inch inspection cover at front of tank;
(7) stainless steel internal piping and overflow, with cleanouts front and rear;
(8) drafting line for suction bottom loading;
(9) components inside tank provide for thorough mixing (sparging) of tank amendment solutions, as well as
cleaning and rinsing of tank interior;
(10) upper spray bar provides pressure discharge with flexible/adjustable spray patterns, for dust control;
(11) lower spray bar provides pressure or gravity discharge, for soil stabilizers or de-icing agents;
(12) hose reel with 70 ft (21.4 m) hose for power washing operations;
(13) cab-mounted control panel for water distributor operations; and
(14) provisions to mount optional attachments: front-mounted disc to cultivate soil, blade for road grading
operations, and de-icing extensions.
j. When sectionalized, the tractor can be driven using front and rear skids for stability, and steered using a skid steer
system.
0002 00-3
TM 5-3800-205-23-1
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS (SCRAPER)
4
3
5
2
390-1008
9 6 8 7
KEY COMPONENT DESCRIPTION
1 Service Headlights Top pair of lights are high beam. Bottom are low beam.
2 Blackout Drive Light Used when operating in blackout mode.
3 Windshield Protects operator from inclement weather and flying objects. Includes
windshield wipers. Can be removed in preparation for transport.
4 ROPS/FOPS Provides rollover and falling object protection for operator. Can be
removed in preparation for transport.
5 Bowl High-strength steel construction with 11 yd3 (8.4 m3) capacity. Low
profile design with wide cutting edge maximizes speed and efficiency
of self-loading.
6 Tiedown D-Rings Used to tie machine down when being air transported.
7 Cab Enclosure contains operator’s seat and all driving and scraper controls.
8 Steps Provide access to cab.
9 Parking/Turn Signal and Serve as parking lights and flash to indicate direction machine is
Blackout Marker Lights turning. In blackout mode, bottom of light serves as blackout markers.
0002 00-4
TM 5-3800-205-23-1
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS (SCRAPER) - CONTINUED

11
12
10
15
14
13
390-1008
17 13 16 15
10 Side Mirror Provides operator with a view to rear and side of machine.
11 Lift Points Attachment points for overhead lifting of ROPS/FOPS.
12 Draft Frame Joins tractor hitch to scraper bowl.
13 Lift/Tiedown Points Provide for slinging or tiedown of machine.
14 Planetary Wheel Ends Power front driving axle.
15 Grabhandles Provide a handhold for personnel climbing on machine.
16 Decontamination Apparatus Provides mounting for Portable Decontamination Apparatus (DAP).

Mounting Bracket
17 Towing Lugs Provide attachment point for medium-duty towbar.
0002 00-5
TM 5-3800-205-23-1

19 20 21
18
390-1009
18 Steering Cylinder Two hydraulic cylinders provide for 90-degree right or left turns with
articulated frame steering system.
19 Work Lights Illuminate cutting edge and loading area of scraper bowl.
20 Elevator Guard Reduces spillage when elevator is lifting earth into bowl during self-
load.
21 Elevator Two-speed, chain-operated elevating mechanism is engaged for all

loading/discharging operations. Flights on elevator carry soil from
cutting edge up and into bowl. Breaking action of elevator flights
during loading results in less chunky material and easier spreading at
fill and compaction. Elevator reverses direction to aid ejection. Can
be reduced in height for transport
0002 00-6
TM 5-3800-205-23-1
22
23
25
390-1009
26 25 24
22 Elevator Speed Reducer and Powers elevator at two forward speeds and one reverse speed. Motor
Motor can be removed in preparation for transport.
23 Ejector Hydraulically-operated back wall of bowl moves forward to push load

from bowl during unloading/spreading operations. Can be reduced in
height for transport.
24 Bowl Retracting Floor Retracts, as ejector moves forward, to facilitate dumping operations.
25 Bowl Lift Cylinders One on each side lower bowl to desired height for self-loading.
Cylinders raise bowl for haul to dump (fill) area.
26 Bowl Cutting Edge Leading edge at bottom of bowl floor. Three types of cutting edges
can be configured, depending on soil type and depth of cut desired:
straight edge (low penetration/finishing operations), stinger edge
(center cutting edge extended - medium penetration), and teeth edge
(high penetration). Distance between cutting edge and elevator flights
may be adjusted to accommodate differing soil conditions.
0002 00-7
TM 5-3800-205-23-1

29
30
28
27 27
31
390-1010
27 Sling Points Attachment points for overhead slinging during external air transport
by CH-47 helicopter. There are two on front and two on rear of
machine.
28 Composite Lights Outside light serves as parking light and turn signal. Middle light is
service light. Inside light is brake light. Used when operating in
standard mode.
29 Blackout Marker Lights Used when operating in blackout mode.
30 Fuel Tank Fill Tube Provides means to fill fuel tank. Tube is removed for airdrop by C130
aircraft.
31 BII Toolbox Provides stowage for all BII items or tools required for transport
preparations.
0002 00-8
TM 5-3800-205-23-1
35 32
390-1010
34 33
32 Hydraulic Motor Stowage Provides stowage for elevator speed reducer hydraulic motor during
Location certain modes of transport.
33 Push Block Used ONLY during machine recovery operations, by push tractor, if
machine is stuck in sand or mud. NEVER use push block to push-load
scraper.
34 Tiedown Points Provide for tiedown of machine.
35 Rear Compartment Access Provides access to fuel and brake system components for service or
Door maintenance.
0002 00-9
TM 5-3800-205-23-1

36 37
15
38
14
390-1011
42 41 39
40
36 Exhaust Stack Direct exhaust away from machine. Can be removed in preparation for
transport.
37 Hitch Joins tractor to draft frame.
38 Engine Access Door Provides access to engine compartment.
39 NATO Slave Receptacle Provides connection point for NATO slave cable to slave start
machine.
40 Engine Air Precleaner Provides convenient means to remove debris filtered from incoming
air to engine.
41 Engine Air Filter and Battery Enclosure provides access to engine air filter primary and secondary
Compartment elements and to batteries for servicing.
42 Hydraulic Tank Stores hydraulic fluid used in machine hydraulic systems. Contains
sight gage for fluid level check.
0002 00-10
TM 5-3800-205-23-1
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS (WATER DISTRIBUTOR)
4
3 5
6
2
1
8 7
10
9
7
10
1 Parking/Turn Signal and Serve as parking lights and flash to indicate direction machine is
Blackout Marker Lights turning. In blackout mode, bottom of light serves as blackout markers.
2 Service Headlights Top pair of lights are high beam. Bottom are low beam.
3 Windshield Protects operator from inclement weather and flying objects. Includes
windshield wipers. Can be removed in preparation for transport.
4 ROPS/FOPS Provides rollover and falling object protection for operator. Can be
removed in preparation for transport.
5 Cab Enclosure contains operator’s seat and all driving and scraper controls.
6 Tank Has a maximum capacity of 2525 gallons (9,558 liters).
7 Tiedown D-Rings Used to tie machine down when being air transported.
8 Draft Frame Joins tractor hitch to water distributor.
9 Tank Lift Cylinders Raise and lower front of tank.
10 Steps Provide access to machine.
0002 00-11
TM 5-3800-205-23-1
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS (WATER DISTRIBUTOR) - CONTINUED
12
15
13 14
16
11
17 (HIDDEN)
21 20 18 12
19
11 Lift Points Attachment points for overhead lifting.
13 Inspection Cover 20-inch opening allows inspection of tank interior.
14 Access Cover 20-inch opening for top loading and adding amendments to tank.
15 Handrails Provide a handhold for personnel climbing onto tank. Can be removed
in preparation for transport.
16 Stowage Tubes Stowage location for four suction hose lengths.
17 Suction Inlet Camlock fitting allows attachment of pressurized water line or suction
hose during bottom loading of tank. Suction hose foot valve is stowed
at suction inlet when not in use.
18 Planetary Wheel Ends Power front driving axle.
19 Blackout Drive Light Used when operating in blackout mode.
20 Decontamination Apparatus Provides mounting for portable decontamination apparatus (DAP).

Mounting Bracket
21 Towing Lugs Provide attachment point for medium-duty towbar.
0002 00-12
TM 5-3800-205-23-1
26 27
24 29
25 24 28
23 30
22
31
22 Work Lights Illuminate rear of water distributor.
23 Composite Lights Outside light serves as parking light and turn signal. Middle light is
service light. Inside light is brake light. Used when operating in
standard mode.
24 Sling Points Attachment points for overhead slinging during external air transport
by CH-47 helicopter. There are two on front and two on rear of
machine.
25 Rear Steps and Platform Provides access to top of tank.
26 Blackout Marker Lights Used when operating in blackout mode.
27 Steering Cylinders Two hydraulic cylinders provide for 90-degree right or left turns with
articulated frame steering system.
28 Water Distributor Control Provides operator control of water distributor valves from inside the
Panel cab. Includes water tank level gage.
29 Exhaust Stack Directs exhaust away from machine. Can be removed in preparation
for transport.
30 Side Mirror Provides operator with a view to rear and side of machine.
31 Engine Air Precleaner Provides convenient means to remove debris filtered from incoming
air to engine.
0002 00-13
TM 5-3800-205-23-1

32
33
34
35
(HIDDEN)
36
42
37
41
40
39 390-1112
38

32 Lift Points Attachment points for overhead lifting of ROPS/FOPS.
33 Engine Access Door Provides access to engine compartment.
34 Engine Air Filter and Battery Enclosure provides access to engine air filter primary and secondary
Compartment elements and to batteries for servicing.
35 NATO Slave Receptacle Provides connection point for NATO slave cable to slave start
machine.
36 Hydraulic Tank Stores hydraulic fluid used in machine hydraulic systems. Contains
sight gage for fluid level check.
37 Fuel Tank Fill Tube Provides means to fill fuel tank.
38 Mudflaps Reduce spray from water and debris.
39 Hose Reel Provides stowage for 70 ft (21.4 m) hose, used in power washing
operations.
40 BII Toolbox Provides stowage for all BII items or tools required for transport
preparations.
41 Lower Spray Bar Provides soil stabilization by pressure discharge of soil stabilization
solutions. May also be used for de-icing operations, with or without
optional extensions.
42 Upper Spray Bar Provides dust control by spraying water and dust palliatives from four-
way adjustment fan-type spray heads.
0002 00-14
TM 5-3800-205-23-1
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS (ISU-60 CONTAINER) - CONTINUED
2 3 4
1
1 ISU-60 Container Cabinet type enclosure used for storage and shipment of transport
supplies and equipment.
2 HAZMAT Access Door Allows access to auxiliary fuel tank.
3 Lifting Rings One ring at each top corner of container provides hookup point for
sling assembly when lifting container using crane or helicopter.
4 Winching Rings Bottom rings allow fully loaded container to be pulled into position
on roller conveyors. Rings along top edge of container roof are used
as tiedowns.
5 Folding Steps Provide access to roof for sling leg rigging and hookup when lifting
container.
0002 00-15
TM 5-3800-205-23-1
EQUIPMENT DATA
Overall:
Length (Tractor and Water Distributor). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.9 ft (10.64 m)

Width (Tractor and Water Distributor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 ft (2.59 m)
Wheelbase (Tractor and Water Distributor). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.7 ft (6.92 m)
Height:
Tractor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7 ft (2.96 m)
Water Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.0 ft (2.74 m)
Weight (Empty):
Tractor and Water Distributor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33505 lb (15198 kg)
Weight (Loaded):
Tractor and Water Distributor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55760 lb (25292 kg)
Fording Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.28 ft (1.00 m)
Maximum Travel Speeds:
Empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.5 mph (38 kph)
Loaded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1 mph (34 kph)
Turning Width, Curb-to-Curb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.7 ft (15.45 m)
Air Mobile:
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.9 ft. (10.64 m)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 ft (22.59 m)
Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.8 ft (6.95 m)
Height:
Tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 ft (2.44 m)
Water Distributor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4 ft (2.26 m) w/o handrails
Weight (Empty):
Tractor and Water Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33985 lb (15415 kg)
Airdrop:
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.96 ft (10.64 m)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 ft (2.59 m)
Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.8 ft (6.95 m)
Height:
Tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6 ft (2.32 m)
Weight (Empty):
Tractor and Water Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33085 lb (15007 kg)
0002 00-16
TM 5-3800-205-23-1
EQUIPMENT DATA - CONTINUED
Overall - Continued
Air Assault:
Length:
Tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.8 ft (7.25 m)
Water Distributor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.7 ft (6.00 m)
Width:
Tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5 ft (2.59 m)
Water Distributor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 ft (2.50 m)
Height:
Tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.0 ft (2.44 m)
Weight (Empty):
Tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16637 lb (7546 kg)
Water Distributor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16495 lb (7482 kg)
Tractor:
Engine:
Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Caterpillar Inc.
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3116TA
Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 hp (131 kw) @ 2300 RPM
Rated Engine RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2450 (high idle); 825 (low idle)
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403 CID (6.6 l)
Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1874 lb (851 kg)
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unit injection
Cooling System, Thermostat Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165°-210° F (74°-99°C)
Transmission:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 speeds forward, 1 reverse
Range Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . powershift, manual
Final Drive:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . planetary/outboard
Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . full-floating
Brakes:
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . air-over-oil actuated, caliper disc
Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . spring actuated, drum
Tires (Tractor and Water Distributor):
Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Firestone
Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.5R25
Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 psi (310 kPa)
Steering:
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . two double-acting hydraulic
cylinders
0002 00-17
TM 5-3800-205-23-1
EQUIPMENT DATA - CONTINUED
Tractor - Continued:
Capacities:
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 gal. (250 l)
Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9 gal. (38 l)
Final Drive (Each) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 gal. (6 l)
Front Axle Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 gal. (19 l)
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.5 gal. (93 l)
Engine Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 gal. (30 l)
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 gal. (35 l)
Electrical System:
System Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 volt
Batteries:
Quantity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 volt
Cold Cranking Amps Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 950 CCA
Water Distributor:
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2525 gal. (9,558 l)
Self-Load Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 minutes
Gravity Drain Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 minutes
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 850 gpm
Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cultivator; cutting edge assembly;
and de-icing extensions
ISU-60 Container:
Overall Dimensions:
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60.00 in. (152.40 cm)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108.00 in. (274.32 cm)
Depth. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.00 in. (223.52 cm)
Weight (Empty) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,260 lb (572 kg)
Maximum Capacity (w/Storage Items). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10,000 lb (4,535 kg)
Gross Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11,260 lb (5,108 kg)
Shelf Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 lb (340 kg)
Transport Requirements:
Military Air Transportability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463L Military Aircraft Restraint
System
Commercial Air Transportability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 747 commercial freighter
Forkliftable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12,000 lb (4,535 kg) capacity fork
truck with 72 in. (182.88 cm) tines
Stackable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum two high with optional
stacking rack (PN 60210-001)
END OF WORK PACKAGE
0002 00-18
TM 5-3800-205-23-1
THEORY OF OPERATION 0003 00
INTRODUCTION
1. The scraper consists of the following functional systems: engine; power train; air and brake systems; electrical system;
and steering and scraper hydraulic systems.
2. This work package explains how the systems and components of the machine work together. A functional description is
provided for each major component and system.
ENGINE
1. General. The tractor is equipped with a Caterpillar® 3116TA turbocharged diesel engine with six in-line cylinders, gen-
erating 175horsepower @ 2300 RPM.
OIL LEVEL THERMOSTAT GOVERNOR OIL FILL ENGINE CRANKCASE

TURBOCHARGER
GAGE BREATHER
OIL WATER
FILTER PUMP
390-404
RIGHT SIDE LEFT SIDE
ENVIRONMENTAL
DRAIN
2. Fuel System. The engine is powered with a direct fuel injection system. Fuel from the fuel tank is pulled through a fuel/
water separator and two secondary fuel filters by an electric fuel pump and the fuel transfer pump that is an integral part
of the engine governor. Drilled passages in the cylinder head provide continuous flow of fuel to the injectors. Unused
fuel is returned to the fuel tank.
0003 00-1
TM 5-3800-205-23-1
THEORY OF OPERATION - CONTINUED 0003 00
ENGINE - CONTINUED
3. Cooling System. The cooling system consists of a belt-driven circulating water pump, 165°F-210°F (74°C-99°C) ther-
mostat for controlling coolant flow, engine-driven fan, oil cooler, and radiator. The cooling system cools the engine by
circulating pressurized ethylene glycol based coolant through the engine and radiator.
OUTLET TO
RADIATOR
CYLINDER THERMOSTAT
HEAD
BYPASS
HOSE THERMOSTAT
(PARTIALLY OPEN)
THERMOSTAT
HOUSING
BYPASS HOSE
RADIATOR
CYLINDER OIL
BLOCK WATER WATER PUMP
COOLER PUMP
390-405 00697239
4. Lubrication System. The engine lubrication system consists of a gear-driven oil pump, oil filter, oil cooler, and oil pan.
The engine is lubricated by cooled and pressurized oil which is circulated through the engine block and head.
5. Exhaust System. The exhaust system removes exhaust gases from the engine through the exhaust manifold and turbo-
charger. The gases flow into exhaust pipes and a muffler to the atmosphere above the cab.
POWER TRAIN
1. General. Power from the engine is sent to the torque converter. The converter output is connected to the upper drive
shaft that moves the power to the six-speed powershift transmission. The transmission is connected to transfer gears that
direct the power via the lower drive shaft to the differential in the drive axle. The differential and drive axles provide the
power to the planetary carriers in the left and right final drives.
2. Transmission. The transmission has six hydraulically activated clutches that provide six speeds forward and one speed
reverse. The speed and direction are manually selected.
3. Transfer Gears. The transfer drive gear receives power from the transmission output and transfers the power via a
transfer gear and shaft to the drive shaft yoke that is connected to the lower drive shaft. The transfer also mounts the
parking brake actuator, drum, and shoes.
4. Differential. The differential divides the balance of power that is sent to the final drives and wheels. When the machine
is turning, the differential allows the inside wheel to turn at a slower rate than the outside wheel. However, the differen-
tial still sends the same torque to each wheel.
5. Differential Lock. The differential lock is utilized when maximum traction is needed. The operator engages the differ-
ential lock by pressing down and holding the differential lock pedal. This in turn allows air pressure to engage the lock;
when the pedal is released, internal springs will disengage the lock. The differential lock should never be engaged when
one tractor wheel is spinning or when operator is turning (steering) machine; this action would result in damage to the
differential assembly.
0003 00-2
TM 5-3800-205-23-1
POWER TRAIN - CONTINUED

6. Final Drive. The planetary final drive causes speed reduction and an increase in torque at the tractor wheels. Power
from the differential turns the axle shafts; the shafts turn the sun gear in the center of the planetary gears. The movement
of the planetary gears causes the planetary carrier to turn; in turn the wheels are turned.
TORQUE
CONVERTER
DRIVE
SHAFT ENGINE
PLANETARY
TRANSMISSION
TRANSFER
GEARS
WHEELS
FINAL
DRIVE
DRIVE PINION 00577880
SHAFT DIFFERENTIAL
GEAR
0003 00-3
TM 5-3800-205-23-1
AIR AND BRAKE SYSTEMS

1. General. The air system consists of an engine-driven air compressor, three air tanks (wet, dry, and reserve), and related
lines, hoses, and valves. The system provides the required air to operate the machine’s service and parking brakes, dif-
ferential lock, operator’s seat, and air horn.
390-1046
0003 00-4
TM 5-3800-205-23-1
AIR AND BRAKE SYSTEMS - CONTINUED

2. Service Brakes. The service brakes are an air-over-fluid activated caliper disc brake system. Each caliper has six pis-
tons and two friction linings. There are three pistons and one friction lining on each side of the rotating brake disc.
ANCHOR HEAD
BOLTS (2)
PINS (2) ASSEMBLY
PISTON
SEALS
PISTONS
(6)
FRICTION
LININGS (2)
ANCHOR
PINS (2)
DISC
BOLTS (2) 00602001
0003 00-5
TM 5-3800-205-23-1
AIR AND BRAKE SYSTEMS - CONTINUED

3. Parking Brake. The parking brake is an air released/spring applied type of parking brake system. When the parking
brake control knob is pulled out, air pressure is exhausted from the brake cylinder and spring pressure is applied. When
the control knob is pressed in, air pressure is applied to the cylinder and the parking brake is released.
BRAKE LININGS
BRAKE
DRUM
PARKING BRAKE
ACTUATOR
ROD
LEVER
00602114
ELECTRICAL SYSTEM
1. The electrical system consists of two 12-volt batteries connected in series, with negative grounding, providing 24 volts
to operate the electrical systems and components.
2. The system contains all the necessary switches, circuit breakers, fuses, relays, harnesses, and connectors to operate the
machine, including a NATO slave receptacle.
3. The three major systems comprising the electrical system are:
a. starting and charging systems;
b. service, work, and blackout lights; and
c. EMS monitoring and alarm system.
0003 00-6
TM 5-3800-205-23-1
ELECTRICAL SYSTEM - CONTINUED
Alternator
Key Circuit To Machine
Circuit
ALTERNATOR Breaker Electrical
Breaker
Main Systems
Relay
Neutral Starter
Starter Start Switch
Relay Switch
Battery
STARTER NATO Slave Disconnect
MOTOR Receptacle Switch
390-977
HYDRAULIC SYSTEM
1. General.
a. The machine hydraulic system supports both steering and scraper hydraulic systems.
b. The hydraulic system consists of vane pumps; control, check, and spool type valves; filters; hydraulic motor; lines,
hoses, and fittings; oil cooler; and hydraulic tank. Two vane type pumps mounted on the torque converter provide
hydraulic system pressure.
0003 00-7
TM 5-3800-205-23-1
HYDRAULIC SYSTEM - CONTINUED
2. Steering System. The steering system is a variable flow modulated system. This type of system allows the operator
good control for minor steering corrections at fast ground speeds as well as good control while operating at slower
speeds during tight turns.
3. Scraper Hydraulic System. The scraper hydraulic system consists of three primary hydraulic circuits to support
scraper operations: bowl circuit for raising and lowering the bowl; ejector/floor circuit for ejecting material from the
bowl; and elevator circuit for loading and unloading material.
Bowl/Tank
Lift Cylinders Pressure Switch
Ejector Cylinder
Floor Cylinder
Relief
Valve
Control Valve
Elevator
Control
Relief/Vent
Valve
Valves
Steering
Cylinders
Oil Cooler
Steering Pump
Filter
Elevator Pump
Hydraulic Tank
390-1179
END OF WORK PACKAGE
0003 00-8
TM 5-3800-205-23-1
CHAPTER 2
TROUBLESHOOTING PROCEDURES
TM 5-3800-205-23-1

TM 5-3800-205-23-1
TROUBLESHOOTING INTRODUCTION 0004 00
INTRODUCTION
1. Troubleshooting procedures are grouped into tables, containing information you need to fault locate malfunctions on the
613CS Scraper or 613CWD Water Distributor. A Troubleshooting Symptom Index in WP 0006 00 is provided to aid in
locating a malfunction or symptom and direct you to the appropriate troubleshooting table in WP 0007 00.
2. WP 0005 00 contains tests, inspections, and adjustments that may be performed as a function of troubleshooting or
maintenance.
PRELIMINARY TROUBLESHOOTING PROCEDURES
NOTE
Fluid leaks are classified as either Class I, Class II or Class III
Class I: Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops.
Class II: Leakage of fluid great enough to form drops, but not enough to cause drops to drip from item
being checked/inspected.
Class III: Leakage of fluid great enough to form drops that fall from item being checked/inspected.
1. Before starting any specific troubleshooting procedures, perform the following:

a. Visually check for ruptured oil hoses or tubes and for Class II or Class III leaks.
b. Check for mechanical jamming or binding caused by rocks or other foreign matter.
c. Check fluid levels in subject area and service as required (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).
2. Ensure all applicable operator troubleshooting has been performed before proceeding.
EXPLANATION OF TROUBLESHOOTING TABLE COLUMNS
The columns in troubleshooting tables are defined as follows:
1. MALFUNCTION. Indicates fault that has occurred in system/equipment.
2. TEST OR INSPECTION. Indicates test or inspection to be performed to isolate probable cause for fault symptom.
3. CORRECTIVE ACTION. Indicates procedure to correct the problem.
ELECTRICAL TROUBLESHOOTING
1. Analyze the symptoms and conditions and use common sense and logic to determine the most likely cause for the prob-
lem, then troubleshoot that circuit first. The more information you have concerning the problem, the easier it will be to
troubleshoot.
2. Isolate to the subsystem level (in cases where more than one subsystem is involved); next isolate the problem to a single
circuit within the subsystem; then, isolate the problem to the faulty component using the troubleshooting symptom index
(WP 0006 00).
3. Frayed, broken, loose or corroded wiring is a common source of problems in any electrical circuit. Always make visual
inspection before starting detail troubleshooting. Observe in particular contacts to ground. Components with case
grounds are especially troublesome.
CAUTION
When making continuity checks, make sure the test equipment is isolated from power source. Failure to do
so may result in damage to equipment.
4. Most of checks made are voltage checks. Pay particular attention to voltages being checked in procedures. This equip-
ment is a 24-volt system. Instructions prior to the step instruct to disconnect at test point from the potential malfunction-
ing component. Once the check has been made, either repair the component or go to the referenced step. If going to
another step, reconnect connection or do as otherwise instructed, such as install jumper wires using jumper wire kit.
When ready to make the prescribed check, apply power to the circuit (if required). A helper may be required if the
switch or power source is out of reach. Release the power function prior to going on, to avoid damage to equipment.
0004 00-1
TM 5-3800-205-23-1
TROUBLESHOOTING INTRODUCTION - CONTINUED 0004 00
COMPONENT LOCATIONS
Figure 1. General Location of Troubleshooting Components.

1 2
3
4
5
6
7
8
9
36 10
11
12
13
14
35 15
34 16
33
17
18
32
19
20
31
21
22
30
29
28 23
27 24
26
25
0004 00-2
TM 5-3800-205-23-1
COMPONENT LOCATIONS - CONTINUED

KEY COMPONENT LOCATION
1 Blackout Drive Light Left-front side of cab, below windshield.
2 Drive Belts Front of engine.
3 Engine Temperature Switch Right-front side of engine.
4 Start Aid Temperature Switch Right-front side of engine.
5 Coolant Temperature Sender Right-front side of engine.
6 Slave Receptacle Right-front side above wire ladder.
7 Alternator Right-front side of engine.
8 Air Tanks Right-front side below engine compartment.
9 Windshield Washer Pump Inside engine compartment, right side.
10 Windshield Washer Reservoir Inside engine compartment, right side.
11 Air Intake Heater Relay Inside engine compartment, right side below battery disconnect switch.
12 Batteries In compartment on right side of vehicle.
13 Air Cleaner In compartment on right side of vehicle.
14 Fuel Shutoff Solenoid Attached to governor.
15 Air Filter Service Indicator Inside engine compartment, right side.
16 Battery Disconnect Switch Inside engine compartment, right side.
17 Ground Strap Inside engine compartment connected to air intake heater and engine block.
18 Engine Fuel Pressure Switch Left-rear of engine.
19 Torque Converter Temperature Center-rear of engine.
Sender
20 Torque Converter Temperature Center-rear of engine.
Switch
21 Fuel System Pressure Switch Right side of machine below fuel filter.
22 Main (Bowl/Ejector) Control Right side of machine aft of fuel filter.
Valve
23 Cutting Edge Work Light Mounted on top of transfer case.
24 Transmission Speed Sensor Upper right side of transfer case.
25 Bowl Work Light Mounted at rear of hitch.
26 Parking Brake Actuator Rod Connected to parking brake.
27 Parking Brake Mounted on lower rear of transfer case.
28 Ether Canister Inside left fender.
29 Ether Start Valve Inside left fender below ether canister.
30 Elevator/Water Pump Control Inside left fender.
Valve
31 Brake Air Supply Block Solenoid Lower-left side mounted to rear cross-member.
32 Engine Speed Sensor Left-rear of engine.
33 Ejector Detent Pressure Switch Left-center of engine, aft of air compressor.
34 Fuel Level Relay Pressure Switch Left-center of engine, aft of air compressor.
35 Engine Oil Pressure Switch Left-center of engine, aft of air compressor.
36 Steering Control Valve Under cab floor, beneath steering column.
0004 00-3
TM 5-3800-205-23-1
Figure 1. General Location of Troubleshooting Components - Continued.
42
41
40
39
38
37
0004 00-4
TM 5-3800-205-23-1

37 Horn Button Center of steering wheel.
38 Directional Control and Hazard Mounted on left side of steering column.
Flasher
39 Relays: Turn/Flash, Flood Enable, Left of steering column in dash panel.
LO/HI Beam, Horn/Backup
Alarm and Water Wagon Flood
40 Stop Lamp Pressure Switch Bottom of brake pedal below cab floor.
41 Light Switch Lower-right side of steering wheel.
42 Horn Front left under cab, mounted to bumper.
0004 00-5
TM 5-3800-205-23-1
Figure 2. Location of Electrical Components.
3 4 5 7 8
2 6
9
26
10
25
11
24
23
22 12
21
20
13
18,19 14
16 15
17
0004 00-6
TM 5-3800-205-23-1

1 Windshield Wiper Motor Upper-right side of cab interior.
2 Panel Test Switch Switch panel.
3 Flood Lamp Switch Switch panel.
4 Ether Start Aid Switch Switch panel.
5 Air Intake Preheat Switch Switch panel.
6 Test Connector Switch panel.
7 Key Start Switch Right side of cab on switch panel.
8 Circuit Breakers Circuit breakers/fuse panel.
9 Main Relay Circuit breakers/fuse panel compartment.
10 Fuel Pump Relay Circuit breakers/fuse panel compartment.
11 Start Relay Circuit breakers/fuse panel compartment.
12 Fuses Circuit breakers/fuse panel.
13 Emergency Brake Right side of cab on shift control panel.
14 Pressure Switch Attached to emergency brake air valve.
15 Pressure Switch Attached to parking brake air valve.
16 Parking Brake Right side of cab on shift control panel.
17 Horn Solenoid Lower-front left of machine below floor.
18 Electronic Monitor System Mounted at bottom of shift lever.
(EMS) Neutral Switch
19 Transmission Neutral Start Mounted at bottom of shift lever.
Switch
20 Dimmer Switch Lower-left cab floor under foot guard.
21 Windshield Washer Switch Switch panel.
22 Windshield Wiper Switch Switch panel.
23 EMS Action Alarm Mounted behind instrument panel.
24 Backup Alarm Limit Switch In shift console forward of shift lever.
25 Air Inlet Heater Timer Mounted behind instrument panel above EMS action alarm.
26 Fuel Pump Switch Switch panel.
0004 00-7
TM 5-3800-205-23-1
Figure 3. Location of Electrical Components.
2 3 4 5 6
1
14 13 12 11 10 9
8
15 15
16 16
17 17
18 18
0004 00-8
TM 5-3800-205-23-1

1 Alternator Circuit Breaker (60 Circuit breaker/fuse panel.
amp)
2 Key Start Switch Circuit Breaker Circuit breaker/fuse panel.
(10 amp)
3 Turn Lamp Circuit Breaker (20 Circuit breaker/fuse panel.
amp)
4 Blackout and Headlamp Circuit Circuit breaker/fuse panel.
Breakers (15 amp)
5 Main Relay Circuit breaker/fuse panel.
6 Fuel Pump Relay Circuit breaker/fuse panel.
7 Start Relay Circuit breaker/fuse panel.
8 Horn/Backup Alarm Fuse Circuit breaker/fuse panel.
9 Fuel Pump Fuse Circuit breaker/fuse panel.
10 Flood Lamps Fuse Circuit breaker/fuse panel.
11 Windshield Wiper Motor Fuse Circuit breaker/fuse panel.
12 Gages and EMS Fuse Circuit breaker/fuse panel.
13 Water Wagon Fuse Circuit breaker/fuse panel.
14 Ejector Lever Fuse Circuit breaker/fuse panel.
15 High Beam Lamp Front-left and front-right of machine.
16 Headlamp Front-left and front-right of machine.
17 Parking Light Front-left and front-right of machine.
18 Blackout Drive Marker Light Front-left and front-right of machine.
0004 00-9
TM 5-3800-205-23-1
Figure 4. Location of Electrical/Mechanical Components.
2
3
5 4
6
8 7
9 10
10 9
0004 00-10
TM 5-3800-205-23-1

1 Fuel Shutoff Valve Right-rear of machine.
2 Backup Alarm Right-rear of machine below Basic Issue Items (BII) box.
3 Fuel/Water Separator Left-rear of machine under access door.
4 Fuel Pump Left-rear of machine under access door.
5 Brake Fluid Reservoir Left of fuel pump.
6 Fuel Level Sender Top of fuel tank below access plate.
7 Fuel Level Sensor Top of fuel tank connected to fuel level sender
8 Fuel Shutoff Valve Right-rear of machine.
9 Stop/Taillights (Composite) Left-rear and right-rear of machine.
10 Blackout Drive/Blackout Markers Left-rear and right-rear of machine.
END OF WORK PACKAGE
0004 00-11
TM 5-3800-205-23-1
0004 00-12
TM 5-3800-205-23-1
TESTS, INSPECTIONS, AND ADJUSTMENTS 0005 00
INTRODUCTION
1. This work package includes miscellaneous tasks, inspections, and adjustment procedures that are performed in conjunc-
tion with troubleshooting or as a function of maintenance.
2. The following is a list of procedures covered in this work package:
a. Troubleshooting Using Multimeter
b. Differential Lock Check
c. Electronic Monitoring System (EMS) Air System Check
d. Air System Pressure Check
e. Air Compressor Governor Adjustment
f. Air Leakage Checks
g. Parking and Emergency Brake Control Valves Test
h. Steering System Pressure Test
i. Steering Time Check
j. Steering Wheel Force Check
k. Steering Wheel Free Play Check
l. Steering Wheel Slip Check
m. Main Control Valve Test and Adjustment
n. Elevator Operating Speed Check
WARNING
If machine is parked indoors, DO NOT run engine unless exhaust fumes are vented to the outside. Failure to
follow this warning may cause injury or death due to carbon monoxide poisoning.
3. If machine is parked indoors during performance of troubleshooting, vent exhaust fumes to the outside if engine is run-
ning.
TROUBLESHOOTING USING MULTIMETER
1. Introduction.
a. This section applies to troubleshooting machine’s starting and charging circuits using a multimeter. It can be
applied to a machine that can self-start, and to a machine that cannot self-start. When using these procedures for a
machine that cannot self-start, refer to TM 5-3800-205-10-1 or TM 5-3800-205-10-2 for slave starting procedures.
0005 00-1
TM 5-3800-205-23-1
TESTS, INSPECTIONS, AND ADJUSTMENTS - CONTINUED 0005 00
TROUBLESHOOTING USING MULTIMETER - CONTINUED

b. Results of the following tests could indicate replacement of components. Before replacing any components, check
for loose or corroded connectors in circuit that indicates a defect. If any loose or corroded connectors are found,
clean/reconnect connectors and retest. Check all ground points to ensure that they are clean and free of CARC
paint.
FRONT FACE OF FUEL SHUTOFF SOLENOID
TEST CONNECTOR PIN LOCATION
390-1740 390-1741
2. Starter Ground Circuit Voltage Test.
NOTE
This test measures voltage drop in ground lead of starter.
a. Ensure engine is OFF.

b. Place battery disconnect switch in ON position.
c. Turn all accessories OFF.
d. Remove wire from upper terminal (GND Negative) on engine fuel shutoff solenoid.
e. Remove protective cap from test connector receptacle.
f. Select VDC on multimeter.
g. Connect positive (red) lead from multimeter to test connector pin 7.
h. Connect negative (black) lead from multimeter to test connector pin 3.
CAUTION
DO NOT crank starter motor for more than 30 seconds at a time. After 30 seconds, allow starter motor to
cool for at least two minutes before attempting to start engine again. Excessive heating of starter motor may
result in damage or premature starter failure.
NOTE
Tachometer will indicate no more than 400 RPM for this test.
i. Using key start switch, crank engine and observe multimeter for an indication more than 1.30 volts. If indication is
more than 1.30 volts, problem could be:
0005 00-2
TM 5-3800-205-23-1

(1) Corroded ground cable-to-frame connection. Clean ground cable-to-frame connection (WP 0033 00)
and retest.
(2) Frayed or cut ground cable. Replace ground cable (WP 0033 00) and retest.
(3) Battery disconnect switch has excessive voltage drop. Replace battery disconnect switch (WP 0037
00).
j. Remove test leads from test connector.
k. Install test connector protective cap.
l. Connect wire to upper terminal (GND Negative) of engine fuel shutoff solenoid.
3. Batteries Voltage Test.
NOTE
This test measures TERMINAL voltage of batteries.

CAUTION
NOTE
During engine cranking, it is normal for battery voltage to go below 23.1 volts. However, if battery voltage
then goes below 12.5 volts, batteries will probably have cranked engine only momentarily.
i. Using key start switch, crank engine and observe multimeter for an indication of less than 23.1 volts. If indication
is less than 23.1 volts, problem could be:
(1) A light or accessory was left ON, while machine was shut down, causing batteries to discharge. Recharge
batteries (WP 0067 00) and retest.
(2) Worn out batteries that will not hold a charge. Replace batteries (WP 0067 00) and retest.
(3) No alternator output. Replace alternator (WP 0034 00).
l. Connect wire to upper terminal (GND Negative) of engine fuel shutoff solenoid.
0005 00-3
TM 5-3800-205-23-1
4. Alternator Circuit Breaker Voltage Test.
NOTE
• Tachometer will indicate zero for this test.
• This test measures a voltage drop of either polarity across alternator circuit breaker.
d. Remove protective cap from test connector receptacle.
e. Select VDC on multimeter.
f. Connect positive (red) lead from multimeter to test connector pin 1.
g. Connect negative (black) lead from multimeter to test connector pin 9.
NOTE
A thirty (30) minute cool down time may be required before circuit breaker can be reset.
h. Observe multimeter for an indication of more than 0.45 volts. If indication is more than 0.45 volts, problem could
be:
(1) A tripped circuit breaker. If circuit breaker is tripped, reset circuit breaker and retest.
(2) A closed circuit breaker with excessive voltage drop. Replace circuit breaker (WP 0038 00).
i. Remove test leads from test connector.
j. Install test connector protective cap.
5. Key Start Switch Circuit Breaker Voltage Test.
NOTE
• This test measures voltage drop across key start switch circuit breaker.
0005 00-4
TM 5-3800-205-23-1
NOTE
i. Observe multimeter for an indication of more than 0.75 volts. If indication is more than 0.75 volts, problem could
be:
(1) A tripped circuit breaker. If circuit breaker is tripped, reset circuit breaker and retest. If problem still exists,
replace circuit breaker (WP 0038 00).
(2) A closed circuit breaker with excessive voltage drop. Replace circuit breaker (WP 0038 00).
l. Connect wire to upper terminal (GND Negative) on engine fuel shutoff solenoid.
6. Key Start Switch Voltage Test.
NOTE
• This test measures voltage drop across both poles of key start switch.
CAUTION
h. Using key start switch, crank engine and observe multimeter for an indication of more than 2.5 volts. Record indi-
cation.
i. Place key start switch to OFF.
j. Connect positive (red) lead from multimeter to test connector pin 1.
k. Connect negative (black) lead from multimeter to test connector pin 8.
l. Place key start switch to ON.
m. Observe multimeter for an indication of more than 2.5 volts. Record indication.
n. Remove test leads from test connector.
o. Install test connector protective cap.
p. A defect is present if voltage drop between either or both of these two sets of test points is more than 2.5 volts.
Replace key start switch (WP 0043 00).
0005 00-5
TM 5-3800-205-23-1

q. Connect wire to upper terminal (GND Negative) on engine fuel shutoff solenoid.
7. Main Relay Voltage Test.
NOTE
• This test measures voltage drop across main relay.
h. Place key start switch to ON.
NOTE
i. Observe multimeter for an indication of more than 1.3 volts. If indication is more than 1.3 volts, problem could be:
(1) A tripped circuit breaker. If circuit breaker is tripped, reset circuit breaker and retest.
(2) A closed circuit breaker with excessive voltage drop. Replace circuit breaker (WP 0038 00) and retest.
(3) An open relay contact, a closed relay with excessive voltage drop or a relay with welded contacts. Replace
main relay (WP 0045 00) and retest.
8. Engine Temperature Coolant Switch Voltage Test.
NOTE
• Perform this test only when engine coolant temperature is below 100°F (38°C).
• This test measures voltage drop across engine temperature switch.
0005 00-6
TM 5-3800-205-23-1

h. Observe multimeter for an indication of more than 1.3 volts. If indication is more than 1.3 volts, replace engine
temperature switch (WP 0063 00).
i. Remove test leads from test connector.
j. Install test connector protective cap.
9. Start Aid Temperature Switch/Solenoid Voltage Test.
NOTE
• Perform this test only when engine coolant temperature is below 80°F (27°C).
• This test measures voltage drop across start aid temperature switch, and resistance of solenoid
coil.
h. Observe multimeter for an indication of more than 2.5 volts. If indication is more than 2.5 volts, replace start aid
temperature switch (WP 0063 00).
i. Select OHMS on multimeter.
j. Connect positive (red) lead from multimeter to test connector pin 10.
k. Connect negative (black) lead from multimeter to test connector pin 7.
l. Observe multimeter for an indication of more than 300 ohms. If indication is more than 300 ohms, replace start aid
solenoid (WP 0022 00).
m. Remove test leads from test connector.
n. Install test connector protective cap.
10. Starter Relay Voltage Test.
NOTE
This test measures voltage drop across starter relay contacts.

e. Remove protective cap from test connector.
0005 00-7
TM 5-3800-205-23-1

CAUTION
NOTE
i. Using key start switch, crank engine and observe multimeter for an indication of more than 0.45 volts. If indication
is more than 0.45 volts, replace starter relay (WP 0045 00).
11. Starter Solenoid Voltage Test.
NOTE
This test measures voltage drop across starter solenoid contacts.

d. Remove fuel pump fuse (WP 0040 00) to shut OFF fuel supply (engine should crank, but not start).
CAUTION
NOTE
i. Using key start switch, crank engine and observe multimeter for an indication of more than 0.75 volts. If indication
is more than 0.75 volts, replace starter (WP 0035 00).
0005 00-8
TM 5-3800-205-23-1

12. Alternator Voltage Test.
NOTE
This test measures alternator output voltage.

d. Engage parking brake.
e. Ensure transmission select lever is in N (Neutral), and transmission neutral lock control is in locked position (TM
5-3800-205-10-1 or TM 5-3800-205-10-2).
f. Remove protective cap from test connector receptacle.
g. Select VDC on multimeter.
h. Connect positive (red) lead from multimeter to test connector pin 9.
i. Connect negative (black) lead from multimeter to test connector pin 7.
NOTE
Batteries need over two (2) minutes to charge to voltage range required for the following test, especially if
machine being tested was boost started.
j. Start engine.
k. Slowly speed up engine until 2440 RPM is indicated on tachometer.
l. With multimeter connected to pins 9 and 7, observe multimeter for an indication between 26.2 and 28.9 volts. If
indication is less than 26.2 volts (undercharge condition), the problem could be:
(1) Loose or broken alternator drive belts. Tighten or replace alternator belts (WP 0032 00) and retest.
(2) Starter-to-engine block ground cable damaged, loose or missing, Tighten or replace ground cable (WP
0033 00) and retest.
(3) Defective batteries. Charge batteries (WP 0067 00) and retest. If problem still exists, replace batteries
(WP 0067 00).
(4) Defective alternator. Replace alternator (WP 0034 00).
m. If indication is more than 28.9 volts (overcharge condition), replace alternator (WP 0034 00).
n. Allow engine to idle for five (5) minutes before turning engine OFF.
o. Remove multimeter leads from test connector receptacle.
p. Install test connector receptacle protective cap.
13. Starter Solenoid Power Circuit Voltage Test.
NOTE
This test measures voltage drop across starter solenoid pull-in coil.

0005 00-9
TM 5-3800-205-23-1
CAUTION
NOTE
i. Using key start switch, crank engine and observe multimeter for an indication of less than 1.0 volt. If indication is
more than 1.0 volt, the problem could be:
(1) Alternator circuit breaker with excessive voltage drop. Replace alternator circuit breaker (WP 0038
00) and retest.
(2) Start relay with excessive voltage drop. Replace start relay (WP 0045 00) and retest.
DIFFERENTIAL LOCK CHECK
1. Equipment Condition. Bowl/water tank empty (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).
2. Differential Lock Check.
a. Start engine (TM 5-3800-205-10-1 or TM 5-3800-205-10-2) and allow air pressure to reach cut-out pressure of
125 psi (860 kPa).
b. Raise bowl/water tank (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).
c. Place parking brake to OFF.
d. With engine at low idle speed, use steering wheel and articulate machine completely to left and right.
e. With tractor and scraper or water distributor in a straight position, push and hold differential lock pedal down.
0005 00-10
TM 5-3800-205-23-1
EMS AIR SYSTEM CHECK - CONTINUED
PARKING BRAKE DIFFERENTIAL LOCK PEDAL
f. Repeat step d. Machine should resist turning when differential lock is engaged.
g. If machine makes a complete left and/or right articulation, refer to Troubleshooting (WP 0006 00).
h. Release pedal.
i. If machine does not make a complete left and/or right articulation, refer to Troubleshooting (WP 0006 00).
EMS AIR SYSTEM CHECK
1. Tools and Special Tools. Tool kit, general mechanic’s (Item 33, WP 0172 00)
2. EMS Air System Check.
a. Start engine (TM 5-3800-205-10-1 or TM 5-3800-205-10-2) and allow air pressure to reach 75 psi (520 kPa).
NOTE
Action alarm and action light for low air pressure will operate until air pressure is 65 psi (450 kPa).
b. If action alarm and/or action light do not operate, stop engine.
c. Check electrical connections at action alarm, action light, and parking and emergency brake pressure switches.
Check action light bulb. If connections are good and bulb is okay, connect a continuity light across terminals of
one pressure switch.
NOTE
Air pressure must be less than specifications of pressure switches.
d. If continuity light does not come on, replace pressure switch (WP 0047 00).
e. Perform steps c and d for other pressure switch.
f. If action alarm does not operate, connect a continuity light across terminals of pressure switch.
g. If continuity light does not come on, replace pressure switch (WP 0047 00).
h. If action alarm and/or light operate above 60 psi (415 kPa), stop engine.
i. Install a new pressure switch or pressure switches (WP 0047 00).
j. Start engine (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).
k. Allow air pressure to reach approximately 75 psi (520 kPa).
l. Slowly open air tank valve and bleed air pressure.
0005 00-11
TM 5-3800-205-23-1
EMS AIR SYSTEM CHECK - CONTINUED
m. Action alarm and light must operate at 60 psi (415 kPa).
n. Stop engine (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).
o. If action alarm and/or light do not operate at correct pressure, check electrical connections for the following com-
ponents: action alarm, light, and pressure switches. Check bulb for light switch.
p. If connections are good, replace pressure switch or switches (WP 0047 00).
AIR SYSTEM PRESSURE TEST
1. Tools and Special Tools.
a. Tool kit, general mechanic’s (Item 33, WP 0172 00).
b. Tool outfit, hydraulic systems (HSTRU) (Item 35, WP 0172 00).
2. Equipment Condition.
a. Engine OFF (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).
b. Battery disconnect switch in OFF position (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).
3. Air System Pressure Test.
WARNING
Always wear eye protection when draining air tanks. Failure to do so could result in injury.
a. Open three drain valves on air tanks to release air AIR DRAIN
pressure from air tanks. TANKS VALVES
b. Remove drain valve from one air tank.
c. Install bushing and hose assembly to air tank

where drain valve was removed.
d. Connect other end of hose to needle valve.
e. Connect 290 psi (2000 kPa) gage to valve.
f. Start engine (TM 5-3800-205-10-1 or TM 5-

3800-205-2) and allow air pressure to reach cut-
out pressure of 125 psi (860 kPa).
g. Compare indications of air pressure gage on

machine and test gage. The difference between
two gages should not be more than 15 psi (105
kPa). If this condition exists, replace air pressure
gage on machine (WP 0042 00).
0005 00-12
TM 5-3800-205-23-1
AIR COMPRESSOR GOVERNOR ADJUSTMENT

1. Tools and Special Tools. Tool kit, general mechanic’s (Item 33, WP 0172 00).
b. Engine access cover open (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).
c. Air tanks drained (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).
3. Air Compressor Governor Adjustment.
a. Install air pressure gage in accordance with Air System Pressure Test in this work package.
b. Start engine (TM 5-3800-205-10-1 or TM 5-3800-205-10-2) and allow air pressure to reach cut-out pressure of
125 psi (860 kPa).
c. Observe cut-out pressure on machine air pressure gage.
d. Push brake pedal rapidly several times.
e. Observe cut-in pressure on gage. Cut-in pressure should be 100-105 psi (690-725 kPa).
f. If necessary, adjust air compressor governor:
(1) Remove cover from governor.
.
COVER GOVERNOR
0005 00-13
TM 5-3800-205-23-1
AIR COMPRESSOR GOVERNOR ADJUSTMENT - CONTINUED

(2) Loosen locknut on adjustment screw.
LOCKNUT ADJUSTMENT SCREW
390-1611
(3) Turn adjustment screw counterclockwise to raise cut-out pressure. One turn of adjustment screw changes
pressure approximately 20 psi (140 kPa). Cut-in pressure will change by the same amount.
(4) Turn adjustment screw clockwise to lower cut-out pressure. One turn of adjustment screw changes pres-
sure approximately 20 psi (140 kPa).
g. If adjustment screw does not change cut-out pressure, air compressor unloading valves are not working correctly.
h. If no difference between cut-in and cut-out pressure is observed, replace air compressor governor (WP 0083
00).
AIR LEAKAGE CHECKS
1. Materials. Detergent (Item 11, WP 0171 00).
2. Air Leakage Checks.
WARNING
Sudden movement of machine or release of air under pressure can cause injury to personnel on or near
machine. To prevent possible injury, perform procedure before testing and adjusting air system and brakes.
NOTE
You can hear air leakage. Air leakage can be seen when soapy water is applied to connections, valves and
hoses.
125 psi (860 kPa). Once pressure is reached, stop engine.
b. Check for leakage at hoses, lines, and connections between air compressor and tractor air tanks.
c. Check for leakage at hoses, lines, and connections between tractor air tanks and service brake control valve.
0005 00-14
TM 5-3800-205-23-1
AIR LEAKAGE CHECKS - CONTINUED
d. Check for leakage at service brake control valve.
NOTE
If air pressure drops below cut-out pressure of 125 psi (860 kPa), start and run engine until air pressure
reaches cut-out pressure. Once pressure is reached, stop engine.
e. Check for leakage at hoses, lines, and connections between service brake control valve and between air tanks and
relay valves.
f. Check for leakage at valves and pressure switches.
g. Check for leakage at hoses, lines, and connections between service brake control valve and parking/emergency
brake control valves.
h. Release parking brake (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).
NOTE
When checking air valves for leakage, check exhaust passages for restrictions such as mud or dirt. A restric-
tion in an exhaust passage will prevent release of pressurized air during normal operations.
i. Check for leakage at hoses, lines, and connections between parking brake control valve and double check valves.
j. Check for leakage at double check valves.
k. Push and hold service brake pedal. Check for leakage at hoses, lines, and connections between service brake con-
trol valve and scraper/water tank brake actuators.
l. Continue holding service brake pedal and check for leakage at hoses, lines, and connections between service brake
control valve and tractor brake actuators.
m. Release service brake pedal.
PARKING AND EMERGENCY BRAKE CONTROL VALVES TEST

2. Parking and Emergency Brake Control Valves Test.
125 psi (860 kPa).
b. Release parking and emergency brakes (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).
c. Push brake pedal rapidly several times until control knobs automatically move to ON position.
d. Install air pressure gage in accordance with Air System Pressure Test in this work package.
e. Observe pressure indication on test gage.
f. Correct pressure that will automatically engage brakes is 40 psi (280 kPa). If pressure on gage is not correct, oper-
ation of control valve is not correct. Replace control valve (WP 0089 00).
0005 00-15
TM 5-3800-205-23-1
STEERING SYSTEM PRESSURE TEST

b. Shop equipment, common no. 2 (Item 25, WP 0172 00)
3. Steering System Pressure Test.
a. Start engine (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).
b. Move machine to a flat, hard surface.
c. Shut down engine.
WARNING
• DO NOT disconnect or remove any hydraulic system line or fitting unless engine is shut down
and hydraulic system pressure has been relieved. Tighten all connections before applying pres-
sure Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury.
• At operating temperature, hydraulic oil tank is hot. Allow hydraulic oil to cool before discon-
necting any hydraulic lines. Failure to do so could result in injury.
d. Turn steering wheel left and right to relieve any pressure from steering system.
WARNING
Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in
NOTE
• Ensure that fluids are contained during performance of inspection, maintenance, testing,
adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component containing fluids.
• Dispose of all fluids according to local regulations and mandates.
0005 00-16
TM 5-3800-205-23-1
STEERING SYSTEM PRESSURE TEST - CONTINUED

e. Remove protective cap from test port for steering control valve, under left front of tractor.
TEST PORT PROTECTIVE CAP STEERING

CONTROL
VALVE
UNDER LEFT FRONT OF TRACTOR
f. Connect hose assembly and pressure gage to test post.
HOSE ASSEMBLY PRESSURE GAGE
0005 00-17
TM 5-3800-205-23-1
STEERING SYSTEM PRESSURE TEST - CONTINUED
CAUTION
Do not turn steering wheel when engine is running and a low pressure gage is installed in steering cir-
cuit. If steering wheel is turned, pressure of oil to steering cylinders will be too high for a low pressure
gage and it may be damaged.
g. Start engine (TM 5-3800-205-10-1 or TM 5-3800-205-10-2) and operate engine at high idle.
h. Raise bowl/water tank (TM 5-3800-205-10-1 or TM 5-3800-205-10-2) and release brakes.
i. Pressure gage at test port should indicate 135 psi (930 kPa).
j. If pressure indication is out of tolerance, stop machine and shut off engine. Engage parking brake (TM 5-3800-
205-10-1 or TM 5-3800-205-10-2).
k. Remove hose assembly and pressure gage from test port. Install protective cap.
l. Check oil level in hydraulic tank. If oil level is low, add hydraulic oil (WP 0009 00 and WP 0010 00).
STEERING TIME CHECK
1. Tools and Special Tools. Stopwatch.
3. Steering Time Check.
c. Operate engine at high idle. Raise bowl/water tank and release brakes (TM 5-3800-205-10-1 or TM 5-3800-205-
10-2).
NOTE
Notify DS Maintenance if steering time is not within limits.
d. Time for a full turn must be 6.2 to 7.5 seconds. A full turn is from stop to stop. Turning left or turning right must
take the same amount of time. The maximum allowable difference between the steering times is 0.6 seconds.
e. If time is out of tolerance, perform Steering System Pressure Test in this work package.
STEERING WHEEL FORCE CHECK
b. Shop equipment, common no. 1 (Item 24, WP 0172 00).
b. Horn button cover removed (WP 0097 00).
0005 00-18
TM 5-3800-205-23-1
STEERING WHEEL FORCE CHECK - CONTINUED

3. Steering Wheel Force Check.
a. Start engine (TM 5-3800-205-10-1 or TM 5-3800-205-10-2) and operate at low idle speed.
b. Using torque wrench, turn steering wheel nut.
REMOVE HORN
BUTTON COVER
STEERING
WHEEL NUT
NOTE
Torque should be between 25-35 lb-in. (2.8-4.0 Nm).
c. If torque is greater than 102 lb-in. (11.5 Nm), refer to Steering System Troubleshooting (WP 0006 00).
STEERING WHEEL FREE PLAY CHECK

2. Steering Wheel Free Play Check.
c. Raise bowl/water tank and release brakes (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).
d. Run engine at high idle speed.
NOTE
Free play must not exceed 25°.
e. Turn steering wheel from left to right without machine articulation. If free play is more than 25°, refer to
Steering System Troubleshooting (WP 0006 00).
0005 00-19
TM 5-3800-205-23-1
STEERING WHEEL SLIP CHECK

2. Steering Wheel Slip Check.
c. Raise bowl/water tank and release brakes (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).
d. Turn steering wheel right until stops hit. Turn steering wheel left until stops hit.
e. Count rotations of steering wheel. Repeat procedure for right turn. Steering wheel rotations for a turn must not
exceed three full rotations. If number of rotations exceeds three full rotations, steering slip is excessive and steer-
ing system requires troubleshooting (WP 0006 00).
MAIN CONTROL VALVE TEST AND ADJUSTMENT
a. Tool kit, general mechanic’s (Item 33, WP 0172 00)
2. Materials/Parts.
a. Oil, lubricating (Item 24 or 29, WP 0171 00).
b. O-ring.
a. Bowl/water tank empty (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).
b. Bowl/water tank lowered (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).
c. Engine OFF (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).
0005 00-20
TM 5-3800-205-23-1
MAIN CONTROL VALVE TEST AND ADJUSTMENT - CONTINUED

4. Main Control Valve Test and Adjustment.
WARNING
• DO NOT disconnect or remove any hydraulic system line or fitting unless engine is shut down
and hydraulic system pressure has been relieved. Tighten all connections before applying pres-
sure. Escaping hydraulic fluid under pressure can penetrate the skin causing serious injury.
• At operating temperature, hydraulic oil tank is hot. Allow hydraulic oil to cool before discon-
necting any hydraulic lines. Failure to do so could result in injury.
a. Operate control levers in cab to relieve any pressure in hydraulic system.
WARNING
Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in
NOTE
PROTECTIVE TEST PORT
• Ensure that fluids are contained CAP
during performance of inspec-
tion, maintenance, testing,
adjusting and repair of the
machine. Be prepared to collect INLET
the fluid with suitable contain- TUBE
ers before opening any compart-
ment or disassembling any
component containing fluids.
• Dispose of all fluids according
to local regulations and man-
dates.
b. Remove protective cap from test port on inlet
tube of control valve. MAIN
CONTROL
VALVE
0005 00-21
TM 5-3800-205-23-1

c. Install pressure gage on test port.
d. Start engine (TM 5-3800-205-10-1 or TM 5- PRESSURE GAGE
3800-205-10-2) and run at 825 RPM.
e. Completely raise bowl/water tank (TM 5-
3800-205-10-1 or TM 5-3800-205-10-2).
f. Increase engine RPM to 2450.
TEST
PORT
g. Slowly move control lever for bowl/water tank to UP and hold for no more than 5 seconds. Correct pressure
indication should be 2500 psi (17237 kPa).
h. If pressure indication is not correct, relief valve must be adjusted as follows:
(1) Remove locking plug and O-ring from relief valve. Discard O-ring.
(2) Loosen locknut. Turn adjustment screw clockwise to increase pressure or counterclockwise to
decrease pressure.
(3) Tighten locknut after adjustment is completed.
(4) Coat new O-ring with clean oil and install O-ring in locking plug.
(5) Install locking plug on relief valve.
0005 00-22
TM 5-3800-205-23-1
LOCKING PLUG
AND O-RING RELIEF VALVE
LOCKNUT
AND
ADJUSTING
SCREW
(HIDDEN)
i. If pressure of 2500 psi (17237 kPa) cannot be obtained, notify DS Maintenance to replace main control valve.
ELEVATOR OPERATING SPEED CHECK
1. Tools and Special Tools. Tool kit, general mechanic’s (Item 33, WP 0172 00).
2. Personnel Required. Two.
a. Machine parked on hard, level surface (TM 5-3800-205-10-1).
b. Scraper bowl lowered to ground (TM 5-3800-205-10-1).
c. Parking brake applied (TM 5-3800-205-10-1).
d. Wheels chocked (TM 5-3800-205-10-1).
0005 00-23
TM 5-3800-205-23-1
ELEVATOR OPERATING SPEED CHECK - CONTINUED

4. Elevator Operating Speed Check.
a. Place a mark on one link of chain.
b. Start engine (TM 5-3800-205-10-1).
c. Operate engine at high idle RPM (2450 +/- 50 RPM).
d. Operate elevator (TM 5-3800-205-10-1). Observe and record number of chain revolutions for one minute.
Refer to Table 1 for proper elevator operating speeds.
Table 1. Elevator Operating Speeds.
Speed Range Chain RPM
Fast Forward 14 to 15
Slow Forward 7 to 8
Reverse 7 to 8
END OF WORK PACKAGE
0005 00-24
TM 5-3800-205-23-1
TROUBLESHOOTING SYMPTOM INDEX 0006 00
Malfunction/Symptom Troubleshooting Procedure Page
AIR SYSTEM AND BRAKES

Brake Air Pressure Low Alert Indicator, Action Light and Action Alarm Come On During Operation . . . . 0007 00-1
Parking Brake Alert Indicator Does Not Come On When Parking Brake is Engaged . . . . . . . . . . . . . . . . . . 0007 00-1
Parking/Emergency Brake Will Not Apply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-2
Parking/Emergency Brake Will Not Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-2
Service Brakes Do Not Apply Correctly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-3
Service Brakes Do Not Release Correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-5
CHARGING SYSTEM
Alternator Alert Indicator Comes On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-6
COOLING SYSTEM
Coolant Temperature Alert Indicator is On and Action Light Flashes, Indicating Engine is Overheating. . . 0007 00-7
DIFFERENTIAL LOCK CONTROL

Differential Lock Control Will Not Engage When Pedal is Pressed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-8
Differential Lock Control Will Not Disengage When Pedal is Released . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-8
ELECTRICAL SYSTEM
Backup Alarm Will Not Sound When Machine is Placed in Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-9
Blackout Drive Light(s) Do Not Operate When B.O. DRIVE Function is Selected . . . . . . . . . . . . . . . . . . . 0007 00-9
Blackout Drive Marker Light(s) Do Not Operate When B.O. MARKER Function is Selected . . . . . . . . . 0007 00-10
Cutting Edge/Bowl Work Light Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-11
Directional Turn Signal or Hazard Flasher Control are Not Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-12
EMS Action Alarm Does Not Sound After Engine Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-13
EMS Alert Indicators and Action Light Do Not Come On When Panel Test Switch is Placed to On . . . . . 0007 00-13
Horn Will Not Sound When Button is Pressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-14
Headlight(s)/Parking Light(s) Do Not Operate When SER. DRIVE or PARK Functions are Selected . . . 0007 00-14
High Beams Do Not Come On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-14
Stoplights Do Not Operate When Brake Pedal is Pressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-15
Taillights Do Not Come On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-16
Water Distributor Control Panel Light Does Not Come On When Key Start Switch is ON . . . . . . . . . . . . 0007 00-16
Water Distributor Control Panel Water Level Green/Red Panel Indicator Lights Do Not Come On . . . . . . 0007 00-17
Water Distributor Work Lights Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-17
Water Distributor Control Panel Has No Power, With Key Start Switch ON. . . . . . . . . . . . . . . . . . . . . . . . 0007 00-18
Windshield Washer Not Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-18
Windshield Wiper Not Working . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-18
0006 00-1
TM 5-3800-205-23-1
TROUBLESHOOTING SYMPTOM INDEX - CONTINUED 0006 00
Malfunction/Symptom Troubleshooting Procedure Page
ENGINE
Engine Cranks But Fails to Start (Operating Temperature Above 32°F (0°C) . . . . . . . . . . . . . . . . . . . . . . . 0007 00-20
Engine Cranks But Fails to Start (Operating Temperature Below 32°F (0°C) . . . . . . . . . . . . . . . . . . . . . . . 0007 00-20
Engine Does Not Develop Full Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-21
Engine Does Not Idle Properly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-21
Engine Fails to Crank When Key Start Switch is Turned to START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-21
Engine Starts But Dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-22
Engine Starts But Misfires or Runs Rough After Proper Warmup Period . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-23
Excessive Engine Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-23
Excessive Exhaust Smoke (At Normal Engine Operating Speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-23
Excessive Exhaust Smoke (White) During Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-24
Low or No Engine Oil Pressure - Alert Indicator, Action Light and Action Alarm are On . . . . . . . . . . . . . 0007 00-24
SCRAPER SYSTEM
Bowl Control Lever Binds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-25
Bowl Drifts After Control Lever is Released or Centered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-25
Ejector Control Lever Binds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-26
Elevator Control Lever Binds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-26
Elevator Operating Speeds are Too Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-27
Floor Opens During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-27
Oil Temperature is Too Hot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-27
Travel Time of Bowl Cylinders is Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-28
Travel Time of Ejector (Floor) is Slow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-29
STEERING SYSTEM
Machine Slowly Drifts (Either Direction) and/or Wanders or Pulls to One Side On
Level Pavement, Even When Steering Wheel is in Straight Position . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-30
Machine Turns Correctly Under Normal Driving Conditions, But Turns Slowly With a Load . . . . . . . . . . 0007 00-30
Machine Turns Slowly in Both Directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-30
Machine Turns Slowly in One Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-32
Steering is Erratic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-32
Turning Steering Wheel is Difficult . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-33
SUSPENSION SEAT
Seat Air Compressor Will Not Come On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-34
Seat Moves to Left or Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-34
Seat Will Not Raise or Lower When Making a Height Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-34
Suspension Ride is Too Hard or Too Soft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-34
TRANSMISSION
Machine Moves When Shift Lever is in NEUTRAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-35
Slow or Erratic Transmission Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-35
Torque Converter Oil Temperature Alert Indicator and Action Light Come On (Indicates Overheating
During Normal Operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-36
0006 00-2
TM 5-3800-205-23-1
TROUBLESHOOTING SYMPTOM INDEX - CONTINUED 0006 00
TRANSMISSION - CONTINUED
Transmission Shifting is Rough. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-36
Transmission Does Not Operate in any Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-37
Transmission Does Not Shift From One Direction to Another. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-38
Transmission Does Not Shift From One Speed to Another . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-38
Transmission Engages, But Machine Does Not Move. Engine Stops Running . . . . . . . . . . . . . . . . . . . . . . 0007 00-39
WATER DISTRIBUTOR
Lower Spray Bar Will Not Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-40
Lower Spray Bar Will Not Gravity Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-40
No Pressure Discharge From Lower Spray Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-40
No Pressure Discharge From Left Upper Spray Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-31
No Pressure Discharge From Right Upper Spray Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-31
Pump Control Lever (Elevator Control Lever) Binds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-42
Pump Control Lever (Elevator Control Lever) Will Not Engage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-42
Pump Control Lever (Elevator Control Lever) Will Not Return to Hold Position . . . . . . . . . . . . . . . . . . . . 0007 00-42
Tank Cannot Be Filled Using Pressurized Water Source Through Suction Inlet . . . . . . . . . . . . . . . . . . . . . 0007 00-42
Tank Cannot Be Suction Loaded Using Onboard Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-42
Water Pump Will Not Operate in High Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-43
Water Pump Will Not Operate in Low Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0007 00-43
Water Tank Drifts Up and Down When Tank Control Lever is in Hold Position. . . . . . . . . . . . . . . . . . . . . 0007 00-44
END OF WORK PACKAGE
0006 00-3
TM 5-3800-205-23-1
0006 00-4
TM 5-3800-205-23-1
TROUBLESHOOTING PROCEDURES 0007 00
NOTE
Refer to WP 0004 00 for additional troubleshooting guidance, information, and illustrations that locate
critical components.
Table 1. Air System and Brakes Troubleshooting Procedures.
MALFUNCTION TEST OR INSPECTION CORRECTIVE ACTION
1. Brake Air Pressure Low Alert Indicator,

Action Light and Action Alarm Come On
During Operation.
WARNING
When the action alarm sounds, immediate shutdown of the machine is required to prevent injury to per-
sonnel and/or severe damage to the machine.
NOTE
Alarm and lights operate until air pressure is above 65 psi (448 kPa).
1. Check air pressure gage for an If indication is less than 65 psi

indication less than 65 psi (448 kPa), go to test step 2.
(448 kPa).
2. Perform Air Leakage Checks Repair any leaks found during

(WP 0005 00). Air Leakage Checks. If problem
still exists, go to test step 3.
3. Perform EMS Air System Repair/replace any faulty

Check (WP 0005 00). components as specified in
check (WP 0005 00).
2. Parking Brake Alert Indicator Does Not Come 1. Press EMS panel test switch a. If indicator light comes on, go
On When Parking Brake is Engaged. UP and check if indicator to MALFUNCTION 3 below
light comes on. Release to check parking brake.
switch.
b. If indicator light does not

come on, go to test step 2.
2. Check for loose connection at a. Tighten loose connection.

indicator light.
b. If problem still exists, go to

test step 3.
3. Check if alert indicator light Replace indicator light (WP

is burned out. 0042 00).
0007 00-1
TM 5-3800-205-23-1
TROUBLESHOOTING PROCEDURES - CONTINUED 0007 00
Table 1. Air System and Brakes Troubleshooting Procedures - Continued.
3. Parking/Emergency Brake Will Not Apply.
NOTE
If any malfunctions are noted during operation check, return here for corrective action.
Perform Parking and a. Adjust brake actuator rod

Emergency Brake Control travel (WP 0088 00). If
Valves Test (WP 0005 00). problem still exists, go to
step b.
b. Replace parking/emergency
brake control valve (WP
0089 00). If problem still
exists, go to step c.
c. Replace double check valves

(WP 0092 00). If problem
still exists, go to step d.
d. Adjust brake (WP 0082 00).

If problem still exists, go to
step e.
e. Inspect brake linings for

wear. If linings are worn to
top of rivets, replace brake
linings (WP 0082 00). If
problem still exists, go to
step f.
f. Replace brake actuator (WP

0088 00).
4. Parking/Emergency Brake Will Not Release.
NOTE
Manual release of brakes requires air pressure above 55 psi (379 kPa).
1. Check air pressure gage for an If air tank valve(s) are closed, go
indication of 55 psi (379 kPa). to test step 2.
If indication is less than 55 psi
(379 kPa) ensure that air tank
drain valve(s) are closed.
2. Check adjustment of air If problem still exists after

compressor governor (WP adjustment of governor, go to
0005 00). test step 3.
0007 00-2
TM 5-3800-205-23-1
4. Parking/Emergency Brake Will Not Release - 3. Perform Air Leakage Checks Repair any leaks found during
Continued. (WP 0005 00). Air Leakage Checks. If problem
still exists, go to step 4.
NOTE
If any malfunctions are noted during operation check, return here for corrective action.
4. Perform Parking and a. Adjust brake actuator rod

Emergency Brake Control travel (WP 0088 00). If
Valves Test (WP 0005 00). problem still exists, go to
test step b.
b. Replace parking/emergency
brake control valve (WP
exists, go to step c.
c. Replace double check valves

(WP 0092 00). If problem
still exists, go to step d.
d. Inspect brake linings for

wear. If linings are worn to
top of rivets, replace brake
linings (WP 0082 00). If
step e.
e. Replace brake actuator (WP

0088 00).
5. Service Brakes Do Not Apply Correctly. 1. Check for mud or dirt under a. Clean mud or dirt from under
brake pedal. brake pedal.

test step 2.
2. Check air pressure gage for an If air tank valve(s) are closed, go
indication of 125 psi (860 to test step 3.
kPa). If indication is less than
125 psi (860 kPa), ensure that
air tank drain valve(s) are
closed.
3. Check brake fluid level in a. If fluid levels are low, fill to

brake fluid reservoirs (WP proper level (WP 0009 00
0010 00) and WP 0010 00).

test step 4.
0007 00-3
TM 5-3800-205-23-1
5. Service Brakes Do Not Apply Correctly - 4. Check adjustment of air If problem still exists after
Continued. compressor governor (WP adjustment of governor, go to
0005 00). test step 5.
5. Perform Air Leakage Checks a. Repair any leaks found

(WP 0005 00). during Air Leakage Checks.

test step 6.
NOTE
Be sure to check service brake linings at rear of machine (TM 5-3800-205-23-2 or TM 5-3800-205-23-3).
6. Check service brake linings a. Replace service brake linings

for wear or damage in (WP 0084 00).
accordance with PMCS
annual check (WP 0010 00).

test step 7.
7. Check brake control valve for a. Replace brake control valve

damage. (WP 0090 00).

test step 8.
NOTE
Be sure to check brake calipers at rear of machine (TM 5-3800-205-23-2 or TM 3800-205-23-3).
8. Check brake caliper(s) for a. Replace brake caliper(s)

damage. (WP 0087 00).

test step 9.
9. Check double check valves Replace double check valves

for damage. (WP 0092 00).
0007 00-4
TM 5-3800-205-23-1
6. Service Brakes Do Not Release Correctly. 1. Check for mud or dirt under a. Clean mud or dirt from under
brake pedal. brake pedal.

test step 2.
2. Perform Air Leakage Checks a. Repair any leaks found

(WP 0005 00) during Air Leakage Checks.

test step 3.
NOTE
Be sure to check service brake linings at rear of machine (TM 5-3800-205-23-2 or TM 5-3800-205-23-3).
3. Check service brake linings a. Replace service brake linings

for wear or damage in (WP 0084 00).
accordance with PMCS
annual check (WP 0010 00).

test step 4.
4. Check brake control valve for Replace brake control valve

damage. (WP 0090 00).
NOTE
Be sure to check brake calipers at rear of machine (TM 5-3800-205-23-2 or TM 3800-205-23-3).
5. Check brake caliper(s) for a. Replace brake caliper(s)

damage. (WP 0087 00).

test step 6.
6. Check double check valves Replace double check valves

for damage. (WP 0092 00).
0007 00-5
TM 5-3800-205-23-1
Table 2. Charging System Troubleshooting Procedures.
1. Alternator Alert Indicator Comes on.
NOTE
1. Check that circuit breaker is Reset circuit breaker. If problem

not tripped. still exists, go to test step 2.
2. Check for loose or broken a. Tighten loose drive belt(s)

drive belt(s). (WP 0032 00).
b. Replace broken drive belt(s)

(WP 0032 00).
c. If problem still exists, go to

test step 3.
3. Check for loose connections a. Tighten any loose

at alternator terminals. connections (WP 0034 00).

test step 4.
4. Check alternator “R” terminal If no continuity is indicated, go

for continuity. to test step 5.
5. Using a multimeter, perform Replace circuit breaker if

Alternator Circuit Breaker voltage indication is more than
Voltage Test (WP 0005 00). 0.45 Vdc (WP 0038 00).
0007 00-6
TM 5-3800-205-23-1
Table 3. Cooling System Troubleshooting Procedures.
1. Coolant Temperature Alert Indicator is On 1. Check coolant temperature If indication is above 240° F
and Action Light Flashes, Indicating Engine gage for an indication above (120° C), let engine cool, then go
is Overheating. 240° F (120° C). to test step 2.
2. Check coolant level (TM 5- a. If low, add coolant (TM 5-

3800-205-10-1 or TM 5- 3800-205-10-1 or TM 5-
3800-205-10-2). 3800-205-10-2).

test step 3.
3. Check for loose or broken a. Tighten loose drive belt(s)

drive belt(s). (WP 0032 00).
b. Replace broken drive belt(s)

(WP 0032 00).

test step 4.
4. Check cooling system for a. Repair any coolant system

leaks. leaks.

test step 5.
5. Check engine oil level (TM 5- a. If engine oil is low, fill to

3800-205-10-1 or TM 5- correct level (TM 5-3800-
3800-205-10-2). 205-10-1 or TM 5-3800-205-
10-2).

test step 6.
6. Check transmission oil level a. If transmission oil level is

(TM 5-3800-205-10-1 or TM low, fill to correct level (TM
5-3800-205-10-2). 5-3800-205-10-1 or TM 5-
3800-205-10-2).

test step 7.
7. Check engine temperature If no continuity is observed,

switch for continuity. replace engine temperature
switch (WP 0063 00).
0007 00-7
TM 5-3800-205-23-1
Table 4. Differential Lock Control Troubleshooting Procedures.
1. Differential Lock Control Will Not Engage 1. Check air pressure gage for an If air pressure gage indication is
When Pedal is Pressed. indication of 125 psi (862 okay, go to test step 2.
kPa).
2. Perform Air Leakage Checks Repair any leaks found during

(WP 0005 00). Air Leakage Checks. If problem
3. Check adjustment of air If problem still exists after

compressor governor (WP adjustment of governor, go to
0005 00). test step 4.
4. Perform Differential Lock If check indicates a discrepancy,

Check (WP 0005 00). go to test step 5.
5. Check differential lock a. Adjust differential lock

control valve adjustment. control valve (WP 0080 00).

test step 6.
6. Check differential lock a. Replace differential lock

control valve for damage. control valve if worn or
damaged (WP 0081 00).
b. If problem still exists, notify

DS Maintenance.
2. Differential Lock Control Will Not Disengage 1. Turn machine slightly, while If problem still exists, go to
When Pedal is Released. decreasing engine RPM as an test step 2.
aid in unlocking differential
lock control.
2. Perform Differential Lock If check indicates a discrepancy,

Check (WP 0005 00). go to test step 3.
3. Check differential lock a. Adjust differential lock

control valve adjustment. control valve (WP 0081 00).

test step 4.
4. Check differential lock a. Replace differential lock

control valve for wear or control valve if worn or
damage. damaged (WP 0081 00).

DS Maintenance.
0007 00-8
TM 5-3800-205-23-1
Table 5. Electrical System Troubleshooting Procedures.
NOTE
Backup alarm will not operate if machine is in blackout drive mode.
1. Backup Alarm Will Not Sound When 1. Check if STOP LIGHT or Select STOP LIGHT or SER.
Machine is Placed in Reverse. SER. DRIVE function has DRIVE. If problem still exists,
been selected on lighting key go to test step 2.
pad.
2. Check for blown fuse. a. If fuse is blown, replace fuse

(WP 0040 00).

test step 3.
3. Check continuity and a. If no continuity is found,

adjustment of backup alarm replace backup alarm limit
limit switch. switch (WP 0036 00).
b. Adjust backup alarm limit

switch if required (WP 0036
00).
c. If problem still exists, replace

backup alarm limit switch
(WP 0036 00).
d. If problem still exists, go to

test step 4.
4. Check transmission shift a. Adjust transmission shift

control adjustment (WP control (WP 0069 00).
0070 00).

test step 5.
5. Check alarm, wiring harness, a. Repair or replace damaged

and connectors for damage, wires or connectors (WP
continuity and proper voltage 0033 00).
of 24 Vdc.
b. Replace damaged backup

alarm (TM 5-3800-205-23-2
or TM 5-3800-205-23-3).
2. Blackout Drive Light(s) Do Not Operate

When B.O. DRIVE Function is Selected.
NOTE
A thirty (30) minute cool down time may be required before circuit breaker automatically resets.
0007 00-9
TM 5-3800-205-23-1
Table 5. Electrical System Troubleshooting Procedures - Continued.
2. Blackout Drive Light(s) Do Not Operate When 1. Check that circuit breaker is a. If circuit breaker does not
B.O. DRIVE Function is Selected - Continued. not tripped. reset after thirty (30)
minutes, replace circuit
breaker (WP 0038 00).

test step 2.
2. Check blackout lights for a. Replace burned out bulbs

damage or burned out bulbs. (WP 0052 00, TM 5-3800-
205-23-2 or TM 5-3800-
205-23-3).
b. Replace damaged blackout

light (WP 0052 00, TM 5-
3800-205-23-2 or TM 5-
3800-205-23-3). If problem
3. Check blackout light(s) a. Repair or replace damaged

wiring harnesses and wires or connectors (WP
connectors for damage, 0033 00).
continuity and proper voltage
of 24 Vdc.

test step 4.
4. Check light switch for Replace light switch (WP 0044

damage and continuity. 00).
3. Blackout Drive Marker Light(s) Do Not

Operate When B.O. MARKER Function is
Selected.
NOTE
1. Check that circuit breaker is a. If circuit breaker does not

not tripped. reset after thirty (30)

test step 2.
2. Check blackout drive marker a. Replace damaged lights

lights for damage. (WP 0050 00).

test step 3.
0007 00-10
TM 5-3800-205-23-1
3. Blackout Drive Light(s) Do Not Operate When 3. Check wiring harness and a. Repair or replace damaged
B.O. MARKER Function is Selected - connectors for damage, wires or connectors (WP
Continued. continuity and proper voltage 0033 00).
of 24 +/- 6 Vdc.

test step 4.

NOTE
Lamps will not operate if machine is in blackout mode.
4. Cutting Edge/Bowl Work Light Inoperative. 1. Check if STOP LIGHT or a. Select STOP LIGHT or SER.
SER. DRIVE function has DRIVE.
been selected on lighting key
pad.

test step 2.
2. Check for blown fuse and/or a. Replace fuse (WP 0040 00)
tripped B.O. drive light circuit if required.
breaker.
b. If circuit breaker does not

reset after thirty (30)

test step 3.
3. Check work lights for damage a. Replace burned out/damaged

or burned out lamps. lamps (WP 0057 00 or TM
5-3800-205-23-2).

test step 4.
4. Check wiring harness and a. Repair or replace damaged

connectors for damage, wires or connectors (WP
of 24 Vdc.

test step 5.
5. Check flood enable relay for Replace flood enable relay

damage or shorts. (WP 0048 00).
0007 00-11
TM 5-3800-205-23-1
NOTE
Turn signals or hazard lights will not operate if machine is in blackout mode.
5. Directional Turn Signal or Hazard Flasher 1. Check if STOP LIGHT or a. Select STOP LIGHT or SER.
Control are Not Working. SER. DRIVE function has DRIVE.
been selected on lighting key
pad.

test step 2.
NOTE
2. Check that circuit breaker is a. If circuit breaker will not

not tripped. reset after thirty (30)

test step 3.
3. Check that B.O. drive light a. If circuit breaker does not

circuit breaker is not tripped. reset after thirty (30)

test step 4.
4. Check turn signal/hazard a. Replace damaged/burned out

flasher lights for damaged or bulbs (WP 0051 00).
burned out bulbs.

test step 5.
5. Check wiring harness and Repair/replace damaged wires

connectors for damage, or connectors (WP 0033 00).
of 24 Vdc.
6. Check flasher unit for damage Replace damaged/shorted

or shorts. flasher unit (WP 0041 00).
7. Check turn/flash relay for Replace shorted/damaged relay

shorts or damage. (WP 0048 00).
8. Check turn signal/hazard Replace switch (WP 0051 00).

flasher switch and wiring for
damage or continuity.
0007 00-12
TM 5-3800-205-23-1
6. EMS Action Alarm Does Not Sound After

Engine Startup.
NOTE
It is normal for action alarm and action light to come on and stay on until an air pressure of approxi-
mately 65 psi (448 kPa) is reached. If alarm does not come on, shut engine down.
1. Check for blown fuse. a. Replace fuse (WP 0040 00)

if required.

test step 2.
2. Check action alarm electrical a. Reconnect if required.

connector.

test step 3.
3. Check wiring harness and a. Repair/replace damaged

of 24 Vdc.
b. Replace EMS action alarm

(WP 0055 00).
7. EMS Alert Indicators and Action Light Do 1. Check for blown fuse. a. Replace fuse (WP 0040 00)
Not Come On When Panel Test Switch is if required.
Placed to ON.

test step 2.
2. Check rocker switch for If no continuity is indicated,

continuity. replace rocker switch (WP
0049 00).
0007 00-13
TM 5-3800-205-23-1
8. Horn Will Not Sound When Button is 1. Check horn wiring harness for If horn wiring harness checks
Pressed. continuity and proper voltage okay, go to test step 2.
of 24 Vdc.
2. Check horn solenoid and horn a. If no continuity is indicated,

switch for continuity. for solenoid, replace horn
b. If no continuity is indicated,
for switch, replace horn
switch (WP 0114 00).
9. Headlight(s)/Parking Light(s) Do Not 1. Check lights for damage or a. Replace burned out lamps/
Operate When SER. DRIVE or PARK burned out lamps/bulbs. bulbs. (WP 0050 00, WP
Functions are Selected. 0054 00).
b. Replace any damaged light

assemblies (WP 0050 00,
WP 0054 00).

test step 2.
2. Check wiring harness(es) and a. Repair/replace damaged

of 24 Vdc.

test step 3.
3. Check if light switch ground Tighten ground cable if required.

cable is loose. If problem still exists, go to test
step 4.
4. Check LO/HI beam relay for a. Replace LO/HI beam relay


test step 5.

10. High Beams Do Not Come On. 1. Check that no mud or dirt is a. Clean any mud or dirt from
packed around dimmer around switch.
switch on floor of cab.

test step 2.
0007 00-14
TM 5-3800-205-23-1
10. High Beams Do Not Come On - Continued. 2. Check lights for damage or a. Replace any damaged lights.
burned out lamps/bulbs.
b. Replace any burned out

lamps/bulbs.

test step 3.
3. Check dimmer switch for a. If no continuity exists,

continuity. replace dimmer switch (WP
0053 00).

test step 4.
4. Check LO/HI beam relay for a. Replace LO/HI beam relay


test step 5.
5. Check wiring harness, a. Repair/replace damaged

connectors and light switch wires or connectors (WP
for damage, continuity and 0033 00).
proper voltage of 24 Vdc.

test step 6.

11. Stoplights Do Not Operate When Brake 1. Check stoplights for damage a. Replace burned out bulbs.
Pedal is Pressed. or burned out bulbs. (TM 5-3800-205-23-2 or TM
5-3800-205-23-3).
b. Replace stoplight assembly

(TM 5-3800-205-23-2 or TM
5-3800-205-23-3).

test step 2.
2. Check stop lamp pressure a. Replace stop lamp pressure

switch for damage or shorts. switch (WP 0058 00).

test step 3.
0007 00-15
TM 5-3800-205-23-1
11. Stoplights Do Not Operate When Brake Pedal 3. Check wiring harness, a. Repair/replace damaged
is Pressed - Continued. connectors and light switch wires or connectors (WP

test step 4.

12. Taillights Do Not Come On. 1. Check taillights for damage or a. Replace burned out bulbs
burned out bulbs. (TM 5-3800-205-23-2 or TM
5-3800-205-23-3).
b. Replace taillight assembly

(TM 5-3800-205-23-2 or TM
5-3800-205-23-3).

test step 2.

connectors and light switch wires or connectors (WP

test step 3.

13. Water Distributor Control Panel Light Does 1. Check for burned out bulb. a. If bulb is burned out, replace
Not Come On When Key Start Switch is ON. burned out bulb (TM 5-3800-
205-23-3).
b. If bulb is okay, go to test step

2.
2. Check for blown fuse. a. Replace fuse if required

(WP 0040 00).
b. If fuse is okay, replace control

panel (TM 5-3800-205-23-
3).
0007 00-16
TM 5-3800-205-23-1
14. Water Distributor Control Panel Water 1. Check for burned out bulb(s). a. If bulb(s) is burned out,
Level Green/Red Panel Indicator Lights Do replace bulb(s) (TM 5-3800-
Not Come On. 205-23-3).
b. If bulb(s) is okay, go to test

step 2.
2. Check connector of control a. Reconnect connector if

panel electrical harness at required.
receptacle connector on side
of cab (TM 5-3800-205-10-
2).

test step 3.
3. Check electrical connection a. Reconnect connector if

at tank water level sender for required. If continuity is okay
tightness and continuity (TM and problem still exists, go to
5-3800-205-23-3). step b.
b. Replace water level sender

(TM 5-3800-205-23-3).
15. Water Distributor Work Lights Inoperative. 1. Check for blown fuse. a. Replace fuse (WP 0040 00)
if required.

test step 2.
2. Check work lights for damage a. Replace burned out/damaged

or burned out lamps. lamps (TM 5-3800-205-23-
3).

test step 3.
3. Check wiring harness and a. Repair or replace damaged

of 24 Vdc.

test step 4.
4. Check flood enable relay for Replace flood enable relay

0007 00-17
TM 5-3800-205-23-1
16. Water Distributor Control Panel Has No 1. Check control panel a. Reconnect connector if
Power, With Key Start Switch ON. connection of electrical required.
harness at receptacle
connector on side of cab (TM
5-3800-205-10-2).
b. If problem still exists, replace

control panel (TM 5-3800-
205-23-3).
2. Check for blown fuse. a. Replace fuse (WP 0040 00)

if required.

test step 3.
3. Check harness for damage a. Repair damaged harness

and continuity. (WP 0033 00).
b. If no continuity is observed,
replace control panel (TM 5-
3800-205-23-3).
17. Windshield Washer Not Working. 1. Check for blown fuse. a. Replace fuse (WP 0040 00)
if required.

test step 2.
2. Check windshield washer a. If no continuity is indicated,

switch for continuity. replace switch (WP 0049
00).

test step 3.

connectors and windshield wires or connectors (WP
washer pump for damage, 0033 00). If problem still
continuity and proper voltage exists, go to step b.
of 24 Vdc.
b. Replace windshield washer

pump (WP 0109 00).
18. Windshield Wiper Not Working. 1. Check for blown fuse. a. Replace fuse (WP 0040 00)
if required.

test step 2.
0007 00-18
TM 5-3800-205-23-1
18. Windshield Wiper Not Working - Continued. 2. Check windshield wiper a. Replace (WP 0049 00).
switch for damage and
continuity.

test step 3.

connectors and windshield wires or connectors (WP
wiper motor for damage, 0033 00).
of 24 Vdc.
b. Replace windshield wiper

motor (WP 0110 00).
0007 00-19
TM 5-3800-205-23-1
Table 6. Engine Troubleshooting Procedures.
1. Engine Cranks But Fails to Start (Operating 1. Check that engine is primed If problem still exists after
Temperature Above 32°F (0°C). by placing fuel pump switch engine priming, go to test step 2.
to ON.
2. Check that fuel shutoff valves a. Open fuel shutoff valves (TM
are fully OPEN. 5-3800-205-10-1 or TM 5-
3800-205-10-2).

test step 3.
3. Using a multimeter, perform a. Follow corrective actions as

Starter Ground Circuit described in test procedures.
Voltage Test, Starter Relay
Voltage Test, and Starter
Solenoid Voltage Test (WP
0005 00).

test step 4.
4. Using a multimeter, check If indications are not as

fuel shutoff solenoid GND specified, replace fuel shutoff
and STOP terminals for an solenoid (WP 0017 00).
indication of 10.30 ohms, and
GND and START for 1.55
ohms.
2. Engine Cranks But Fails to Start (Operating 1. Check that fuel shutoff valves a. Open fuel shutoff valves (TM
Temperature Below 32°F (0°C). are fully OPEN. 5-3800-205-10-1 or TM 5-
3800-205-10-2).

test step 2.
CAUTION
DO NOT crank starter motor for more than 30 seconds at a time. After 30 seconds, allow starter motor
to cool for at least two minutes before attempting to start engine again. Excessive heating of starter
motor may result in damage or premature starter failure.
2. While cranking engine, press a. If problem still exists, replace

top of ether start aid switch. ether canister (WP 0022 00),
Wait approximately two (2) then try to start engine.
seconds between injections.

test step 3.
0007 00-20
TM 5-3800-205-23-1
Table 6. Engine Troubleshooting Procedures - Continued.
2. Engine Cranks But Fails to Start (Operating 3. Using a multimeter, perform a. Follow corrective actions as
Temperature Below 32°F (0°C) - Continued. Starter Ground Circuit described in test procedures.
Voltage Test, Starter Relay
Voltage Test, Starter Solenoid
Voltage Test, and Start Aid
Temperature Switch Solenoid
Voltage Test (WP 0005 00).

test step 4.
4. Using a multimeter, check If indications are not as

fuel shutoff solenoid GND specified, replace fuel shutoff
and STOP terminals for an solenoid (WP 0017 00).
indication of 10.30 ohms, and
GND and START for 1.55
ohms.
3. Engine Does Not Develop Full Power. 1. Check for restricted or a. Remove restrictions from
sticking accelerator pedal. accelerator pedal on cab
floor.

test step 3.
2. Check for clogged fuel/water Replace fuel/water separator

separator. (TM 5-3800-205-23-2 or TM 5-
3800-205-23-3).
4. Engine Does Not Idle Properly. 1. Check indication of air filter a. If indicator is red, clean air
service indicator. filter and retest.
b. If problem still exists replace

air filter.

test step 2.
2. Check for clogged fuel/water Replace fuel/water separator

separator. (TM 5-3800-205-23-2 or TM 5-
3800-205-23-3).
5. Engine Fails to Crank When Key Start 1. Check position of battery a. Place battery disconnect
Switch is Turned to START. disconnect switch. switch to ON.
b. If problem still exists. go to

test step 2.
2. Check position of a. Place transmission shift lever

transmission shift lever. in N (Neutral).
0007 00-21
TM 5-3800-205-23-1
5. Engine Fails to Crank When Key Start Switch b. If problem still exists, go to
is Turned to START - Continued. test step 3.
NOTE
3. Check that key start switch a. If circuit breaker doesn’t

circuit breaker is not tripped. reset within thirty (30)

test step 4.
4. Check for dirty, loose, or a. Clean dirty cables (WP 0010

damaged battery cables. 00).
b. Tighten loose connections.
c. Replace cables if damaged

(WP 0067 00).
d. If problem still exists, go to

test step 5.
5. Using a multimeter, perform Follow corrective actions as

Batteries Voltage Test, described in test procedures.
Alternator Circuit Breaker
Voltage Test, Key Start
Switch Circuit Breaker
Voltage Test, Key Start
Switch Voltage Test, and
Main Relay Voltage Test
(WP 0005 00).
6. Engine Starts But Dies. 1. Check for loose electrical If connections are okay, go to
connections at fuel shutoff test step 2.
solenoid.
NOTE
Push in button on solenoid to manually shut off engine. Solenoid cannot be manually latched in run
position for starting.
2. Check position of button on If button is out and problem still

fuel shutoff solenoid. exists, replace fuel shutoff
0007 00-22
TM 5-3800-205-23-1
7. Engine Starts But Misfires or Runs Rough 1. Check fuel/water separator a. Open fuel/water separator
After Proper Warmup Period. for moisture. drain valve and drain water
from separator (TM 5-3800-
205-10-1 or TM 5-3800-205-
10-2).

test step 2.
2. Check for water in fuel. a. Drain secondary fuel filters.

test step 3.
3. Check for air in fuel system Tighten, repair or replace fuel

and restricted fuel lines or system lines and hoses (WP
hoses. 0016 00).
8. Excessive Engine Oil Consumption. 1. Check for loose oil lines/ a. Tighten any loose oil lines/
hoses and oil leaks. hoses.
b. Repair any oil leaks.
c. If problem still exists, notify

DS Maintenance.
2. Check exhaust for blue If smoke is blue, go to test step 3.

smoke.
3. Remove air inlet hose from If oil if found, notify DS

turbocharger and check for Maintenance.
evidence of oil.
9. Excessive Exhaust Smoke (At Normal Engine 1. Check for water in fuel. a. Drain secondary fuel filters.
Operating Speed).

DS Maintenance.
2. Check fuel tank for evidence If water is found in fuel tank,

of water. notify DS Maintenance.
0007 00-23
TM 5-3800-205-23-1
10. Excessive Exhaust Smoke (White) During 1. Check and monitor engine a. Allow engine to warm up to
Startup. operating temperature. operating temperature.
test step 2.
2. Check operation of a. If thermostat is inoperative,
thermostat. replace thermostat (WP
0028 00).
test step 3.
3. Check operation of air inlet If air inlet heater is
heater. malfunctioning, notify DS
Maintenance.
11. Low or No Engine Oil Pressure - Alert
Indicator, Action Light and Action Alarm are
On.
WARNING
When action alarm sounds, immediate shutdown of the machine is required to prevent injury to the
operator and/or severe damage to the machine.
1. Check engine oil level. a. If engine oil is low, fill to
correct level (TM 5-3800-
205-10-1 or TM 5-3800-205-
10-2).
test step 2.
2. Check for external engine oil a. Tighten any leaking oil lines
leaks. or fittings.
test step 3.
3. Check oil pressure switch a. If harness is damaged,
harness for damage and replace harness.
continuity.
replace oil pressure switch
(WP 0064 00).
test step 4.
4. Using a multimeter, check oil If no resistance is observed,
pressure switch resistance. replace oil pressure switch (WP
0064 00).
0007 00-24
TM 5-3800-205-23-1
Table 7. Scraper System Troubleshooting Procedures.
1. Bowl Control Lever Binds. 1. Check for bent or damaged a. If lever is bent or damaged,
lever. replace lever (WP 0114 00).
b. If lever is okay, go to test step

2.
WARNING
Park machine on level ground, stop engine, and lower bowl/water tank to prevent injury to operator
and/or severe damage to machine.
2. Check bowl/ejector main a. Clean debris from control

control valve, inboard of right valve linkage.
fender for buildup of debris.

test step 3.
3. Perform Control Valve Test a. Adjust relief valve setting

and Adjustment (WP 0005 (WP 0005 00).
00).
b. If problem still exists after

adjustment, notify DS
Maintenance to replace main
control valve.
2. Bowl Drifts After Control Lever is Released 1. Check drift of bowl hydraulic If drift exceeds 0.31 in. (7.9
or Centered. cylinders: mm), go to test step 2.
a. Lift bowl 6-10 in. (15-25

cm).
b. Move control lever to hold

position.
c. After three (3) minutes,

make a mark on side of
bowl at bottom of draft
arm. Mark should also be
6 in. (15 cm) from front of
bowl side.
d. After five (5) minutes,

make a measurement for
drift.
e. Drift on a new machine

should not be more than
0.31 in. (7.9 mm).
0007 00-25
TM 5-3800-205-23-1
Table 7. Scraper System Troubleshooting Procedures - Continued.
2. Bowl Drifts After Control Lever is Released or 2. Check bowl hydraulic a. Repair any leaks if required.
Centered- Continued. cylinder(s) for external
leakage.
b. If cylinder(s) are damaged,

replace cylinder(s) (TM 5-
3800-05-23-2).
3. Ejector Control Lever Binds. 1. Check for bent or damaged a. If lever is bent or damaged,

2.
WARNING
2. Check bowl/ejector main a. Clean debris from control

control valve, inboard of right valve linkage.
fender for buildup of debris.

test step b.
3. Perform Main Control Valve a. Adjust relief valve setting

Test and Adjustment (WP (WP 0005 00).
0005 00).

control valve.
4. Elevator Control Lever Binds. 1. Check for bent or damaged a. If lever is bent or damaged,

2.
WARNING
2. Check elevator main control a. Clean debris from control

valve, inboard of left fender, valve linkage.
for buildup of debris.

test step 3.
0007 00-26
TM 5-3800-205-23-1
4. Elevator Control Lever Binds - Continued. 3. Perform Main Control Valve a. Adjust relief valve setting
0005 00).

control valve.
5. Elevator Operating Speeds are Too Slow. 1. Check elevator chain for a. Adjust elevator chain (TM 5-
looseness. 3800-205-23-2).

test step 2.
2. Perform Elevator Operating Go to test step 3.

Speeds Check (WP 0005 00).

0005 00).

adjustment, go to test step 4.
4. Check hydraulic motor If any leakage is found, notify

mounting surface or drain DS Maintenance to replace
plug “WEEP” hole for hydraulic motor.
hydraulic oil leakage.
NOTE
If floor is not closing properly, it may cause premature floor opening
6. Floor Opens During Operation. Check floor area for any buildup a. Clean any debris from floor
of debris that would stop floor area.
from closing.

DS Maintenance to replace
floor check valve.
7. Oil Temperature is Too Hot.
NOTE
Before checking oil level, ensure machine is parked on level ground with parking brake applied, trans-
mission in N (Neutral), oil warm, engine at low idle, ejector moved fully forward, and scraper bowl
lowered with slight downward pressure applied.
1. Check that all control lavers Return control levers to hold

are returning to hold position. position.
0007 00-27
TM 5-3800-205-23-1
7. Oil Temperature is Too Hot - Continued 2. Check hydraulic oil level. a. If oil level is low, fill to
correct level (TM 5-3800-
205-10-1 or TM 5-3800-205-
10-2).
test step 3.
3. Check hydraulic oil viscosity a. If viscosity of hydraulic oil is
in accordance with PMCS not to specification, replace
(WP 0009 00). oil with specified type oil
(WP 0009 00 and WP 0010
00).
test step 4.
4. Check that load on system is a. Reduce load.
not too high.
test step 5.
5. Check for hydraulic oil a. If any leakage is found, notify
leakage at piston seals on DS Maintenance to replace
steering cylinder(s). steering cylinder(s).
test step 6.
6. Perform Steering System Test a. If low pressure output is
(WP 0005 00). indicated, notify DS
Maintenance to replace
steering control valve.
test step 7.
7. Check for air in system. If air is found, notify DS
Maintenance to replace steering
vane pump.
8. Travel Time of Bowl Cylinders is Slow.
NOTE
To verify travel time of bowl cylinders, lower bowl to ground. Run engine at high idle RPM. Use a
stopwatch to verify time required to fully lift bowl. Time required to lift bowl from ground is approxi-
mately 4 seconds.
1. Check bowl hydraulic a. Clean any debris from
cylinders for any buildup of cylinder(s).
debris.
0007 00-28
TM 5-3800-205-23-1
8. Travel Time of Bowl Cylinders is Slow - b. If problem still exists, go to

Continued. test step 2

0005 00).

adjustment, go to test step 3.
3. Check bowl hydraulic If cylinder piston seals are

cylinder piston seals for leaking, replace cylinder (TM 5-
leakage. 3800-205-23-2).
9. Travel Time of Ejector (Floor) is Slow.
NOTE
To verify travel time of ejector (floor), lift bowl approximately 6 in. (152 mm). Make sure that floor
is closed. Run engine at high idle RPM. Move ejector control handle to EJECT position. Use a stop-
watch to verify time required to fully open floor. When bowl is empty, time required to fully open
floor is approximately 6.3 seconds.

0005 00).

Maintenance to replace floor
check valve (TM 5-3800-
205-23-2).

test step 2.
2. Check floor and ejector If cylinder piston seals are

hydraulic cylinder piston leaking, notify DS Maintenance
seals for leakage. to replace cylinder (TM 5-3800-
205-23-2).
0007 00-29
TM 5-3800-205-23-1
Table 8. Steering System Troubleshooting Procedures.
WARNING
Hitch and steering movement can reduce clearances suddenly and cause personal injury. Stop engine
before servicing.
1. Machine Slowly Drifts (Either Direction) 1. Check that tires are proper a. Replace tires with proper size
and/or Wanders or Pulls to One Side On size and type. or type (WP 0096 00, TM 5-
Level Pavement, Even When Steering Wheel 3800-205-23-2, or TM 5-
is in Straight Position. 3800-205-23-3).

test step 2.
2. Check steering linkage for a. Notify DS Maintenance to

damage or binding. repair any damaged linkage.

test step 3.
3. Check centering position and If main spool will not center or

freedom of movement of shows signs of restricted
main control spool in steering movement, notify DS
control valve. Maintenance.
2. Machine Turns Correctly During Normal 1. Possibility of oil leakage past a. Notify DS Maintenance.
Driving Conditions, But Turns Slowly With seat of relief valve in steering
a Load. control valve.

test step 2.
2. Possibility of oil leakage past Notify DS Maintenance.

seals and ball check valve in
3. Machine Turns Slowly in Both Directions.
NOTE
mission in N (Neutral), oil warm, engine at low idle, ejector moved fully forward, and scraper bowl/
water distributor tank lowered with slight downward pressure applied.
1. Check hydraulic oil level. If oil level is low, fill to correct

level (TM 5-3800-205-10-1 or
TM 5-3800-205-10-2).
2. Check for hydraulic oil a. Notify DS Maintenance to

leakage at piston seals on replace steering cylinder(s).
steering cylinder(s).
0007 00-30
TM 5-3800-205-23-1
Table 8. Steering System Troubleshooting Procedures - Continued.
3. Machine Turns Slowly in Both Directions - b. If problem still exists, go to

Continued. test step 3.
3. Check that main control spool a. If spool does not center

in steering control valve is correctly or if any damage is
centered and that there is no found, notify DS
damage to spool. Maintenance to replace

test step 4.
4. Perform Steering System a. If low output pressure is

Pressure Test (WP 0005 00). indicated, notify DS

test step 5.
5. Check for leakage at steering a. If any leakage is found, notify

control valve. DS Maintenance to replace

test step 6.
6. Check valve seat in ball check a. If any damage to valve seat is

valve for damage. found, notify DS

DS Maintenance to replace
steering vane pump.
0007 00-31
TM 5-3800-205-23-1
4. Machine Turns Slowly in One Direction. 1. Check for hydraulic oil a. If any leakage is found, notify
leakage at piston seals on DS Maintenance to replace
steering cylinder(s). steering cylinder(s).
test step 2.
2. Check that main control spool a. If spool does not center
in steering control valve is correctly or if less than full
centered and spool achieves travel of spool was found,
full travel. notify DS Maintenance to
replace steering control
valve.
test step 3.
3. Check for leakage at steering a. If any leakage is found, notify
control valve. DS Maintenance to replace
test step 4.
4. Check for oil leakage past ball If any leakage is found, notify
of steering control valve ball DS Maintenance to replace
check valve. steering control valve.
5. Steering is Erratic. 1. Check tires for proper a. Inflate tires to proper
pressure. pressure (TM 5-3800-205-
10-1 or TM 5-3800-205-10-
2).
test step 2.
2. Check for freedom of a. If main spool shows signs of
movement of main control restricted movement, notify
spool in steering control DS Maintenance to replace
valve. steering control valve.
test step 3.
3. Check for air in steering a. If air is found, notify DS
system. Maintenance to replace
steering vane pump.
test step 4.
4. Perform Steering System a. If low output pressure is
Pressure Test (WP 0005 00). indicated, notify DS
0007 00-32
TM 5-3800-205-23-1
6. Turning Steering Wheel is Difficult. 1. Check for steering column Align steering column linkage
linkage misalinement that (WP 0097 00). If problem still
would cause binding. exists, go to test step 2.
2. Check steering control a. Remove any restrictions

linkage for restricted from steering control
movement. linkage (WP 0097 00).

test step 3.
3. Check for freedom of If main spool shows signs of

movement of main control restricted movement, notify DS
spool in steering control Maintenance to replace steering
valve. control valve.
0007 00-33
TM 5-3800-205-23-1
Table 9. Suspension Seat Troubleshooting Procedures.
1. Seat Air Compressor Will Not Come On. 1. Check for blown fuse. a. If fuse is blown, replace fuse
(WP 0040 00).

test step 2.
2. Check wiring harness for a. Repair any damage to harness

damage and continuity. if required.
replace harness.
c. If harness was okay, replace

air compressor (WP 0104
00).
2. Seat Moves to Left or Right. Check for excessive play a. Loosen mounting bolts for
between upper side plate and rail front and rear stop.
section.
b. Pry against front stop to

remove excessive play, then
tighten front stop bolt.
c. Repeat step b for rear stop.
3. Seat Will Not Raise or Lower When Making Check height control valve ports a. Clean height control valve
a Height Adjustment. for debris. ports of any debris. If
problem still exists, go to step
b.
b. Replace height control valve

(WP 0104 00).
4. Suspension Ride is Too Hard or Too Soft. Check that correct damping is a. Move suspension damping
selected. lever to rear for more
damping, or forward for less
damping.
b. If selecting a different
suspension damping does not
change damping, replace
shock absorber (WP 0104
00).
0007 00-34
TM 5-3800-205-23-1
Table 10. Transmission Troubleshooting Procedures.
NOTE
Prior to removing major assembly, contact Specialized Repair Activity (SRA) for further troubleshoot-
ing information and/or technical assistance. For SRA support, contact the local Caterpillar dealer (WP
0175 00).
1. Machine Moves When Shift Lever is in 1. Check control linkage proper a. Adjust control linkage (WP
NEUTRAL. adjustment (WP 0070 00). 0070 00).

DS Maintenance.
2. Slow or Erratic Transmission Engagement.
1. Check control linkage for a. Repair any damage to control

proper adjustment or damage. linkage (WP 0069 00). If
step b.
b. Adjust control linkage (WP

exists, go to test step 2.
2. Check for loose lines/hoses a. Tighten any loose lines/

on inlet side of transmission hoses.
oil pump.

DS Maintenance.
NOTE
Prior to removing major assembly, contact Specialized Repair Activity (SRA) for further troubleshoot-
ing information and/or technical assistance. For SRA support, contact the local Caterpillar dealer (WP
0175 00).
3. Torque Converter Oil Temperature Alert 1. Observe torque converter oil If temperature exceeds 270° F
Indicator and Action Light Come On temperature gage for (132° C), go to test step 2.
(Indicates Overheating During Normal indication above 270° F (132°
Operation). C).
2. Ensure proper transmission Select proper transmission

range is selected for machine range. If proper range was used,
operation. go to test step 3.
0007 00-35
TM 5-3800-205-23-1
Table 10. Transmission Troubleshooting Procedures - Continued.
3. Torque Converter Oil Temperature Alert

Indicator and Action Light Come On
(Indicates Overheating During Normal
Operation) - Continued.
NOTE
mission in N (Neutral), oil warm, engine at low idle, ejector moved fully forward, and scraper bowl/
water distributor tank lowered with slight downward pressure applied.
3. Check transmission oil level. a. If transmission oil is low, fill

to correct level (TM 5-3800-
205-10-1 or TM 5-3800-205-
10-2).

DS Maintenance.
4. Transmission Shifting is Rough. 1. Check control linkage for a. Adjust control linkage (WP
proper adjustment. 0070 00).

test step 2.
NOTE
Prior to removing major assembly, contact SRA for further troubleshooting information and/or
technical assistance. For SRA support, contact the local Caterpillar dealer (WP 0175 00).
2. Check primary pressure a. Reset modulation relief valve

setting of modulation relief primary setting. If problem
valve. still exists, go to step b.
b. Replace modulation relief

valve.

test step 3.
3. Check for movement of a. If no movement of load piston

pressure control valve load is observed, replace pressure
piston. control valve.

test step 4.
0007 00-36
TM 5-3800-205-23-1
4. Transmission Shifting is Rough - Continued. 4. Check operation of pressure a. If pressure differential valve
differential valve. is inoperative, replace valve.

test step 5.
5. Check pressure control valve If springs are damaged or weak,

springs for damage or replace pressure control valve.
weakness.
5. Transmission Does Not Operate in any 1. Check oil pump and oil pump a. If any damage or wear was
Speed. drive for damage or wear that found, notify DS
would cause low oil pressure. Maintenance to replace oil
pump and oil pump drive
(WP 0149 00)

test step 2.
2. Check inlet side of oil pump a. Notify DS Maintenance to

for air leaks. repair any air leaks to inlet
side of oil pump.

test step 3.
NOTE
3. Check primary pressure a. Reset modulation relief valve

setting of modulation relief primary setting. If problem
valve. still exists, go to test step b.
b. Replace modulation relief

valve.

test step 4.
4. Check operation of pressure a. If pressure control valve is

control valve. inoperative, replace pressure
control valve.

test step 5.
0007 00-37
TM 5-3800-205-23-1
5. Transmission Does Not Operate in any Speed 5. Check for mechanical failure a. Repair any mechanical
- Continued. in transmission. failures found in
transmission.
test step 6.
6. Check for mechanical failure a. If mechanical failures were
in transfer gears. found, replace transfer gears.
test step 7.
NOTE
7. Check for mechanical failures a. If mechanical failures were
in differential. found, notify DS
differential.
test step 8.
8. Check for mechanical failures a. If mechanical failures were
in torque converter. found, notify DS
torque converter.
test step 9.
9. Check for excessive leakage a. Repair any leaks in
inside transmission. transmission. If problem still
exists, go to test step b.
b. Notify DS Maintenance to
replace transmission.
6. Transmission Does Not Shift From One Check control linkage for proper Adjust control linkage (WP
Direction to Another. adjustment (WP 0070 00). 0070 00).
7. Transmission Does Not Shift From One Check control linkage for proper Adjust control linkage (WP
Speed to Another. adjustment (WP 0070 00). 0070 00).
0007 00-38
TM 5-3800-205-23-1
NOTE
8. Transmission Engages, But Machine Does 1. Check for mechanical failure a. If mechanical failures were
Not Move. Engine Stops Running. in output transfer gears. found, notify DS
output transfer gears.

test step 2.

in differential. found, notify DS
differential.

test step 3.

in a final drive. found, replace final drive
(WP 0077 00).

test step 4.
4. Check for mechanical failure If any mechanical failures were

to clutches and gears in found, notify DS Maintenance to
transmission. replace transmission.
0007 00-39
TM 5-3800-205-23-1
Table 11. Water Distributor Troubleshooting Procedures.
1. Lower Spray Bar Will Not Discharge.
NOTE
Refer to component locator for butterfly valve assemblies (TM 5-3800-205-23-3) and get assistance to
check valve indicator position.
Check that indicator on gravity If red indicator is in horizontal

spray valve is horizontal to position and problem still exists,
manifold assembly. replace gravity spray valve (TM
5-3800-205-23-3).
2. Lower Spray Bar Will Not Gravity

Discharge.
NOTE
1. Check that indicator on If red indicator is in horizontal

pressure gravity valve is position and problem still exists,
horizontal to manifold go to test step 2.
assembly.
2. Check for loose air If connections are okay and

connections at pressure problem still exists, replace
gravity valve. pressure gravity valve (TM 5-
3800-205-23-3).
3. No Pressure Discharge From Lower Spray 1. Check that PUMP switch is If switches are in proper position
Bar. ON and PRESSURE and problem still exists, go to
GRAVITY switch is OFF. test step 2.
2. Check that pump control lever If control lever is in proper

(elevator control lever) is in position and problem still exists,
pump on, slow/fast position. notify DS Maintenance to
replace pump.
3. Check for loose air a. If connections are okay and

connections at air valve. problem still exists, replace
pressure gravity valve (TM 5-
3800-205-23-3).

test step 4.

0005 00).
b. If problem still exists, after

control valve.
0007 00-40
TM 5-3800-205-23-1
Table 11. Water Distributor Troubleshooting Procedures - Continued.
4. No Pressure Discharge From Left Upper 1. Check that PUMP switch is If switches are in proper position
Spray Bar. ON, and PRESSURE and problem still exists, go to
NOTE
2. Check that red indicator on If right-side spray valve is closed
right-side spray valve is and problem still exists, go to
vertical to spray bar. test step 3.
3. Check that indicator on left- If red indicator is in horizontal
side spray valve is horizontal position and problem still exists,
to spray bar. go to test step 4.
connections at left-side spray problem still exists, replace left-
valve. side spray valve (TM 5-3800-
205-23-3).
0005 00).
control valve.
5. No Pressure Discharge From Right Upper 1. Check that PUMP switch is If switches are in proper position
Spray Bar. ON, and PRESSURE and problem still exists, go to
NOTE
2. Check that indicator on left- If indicator is vertical and
side spray valve is vertical to problem still exists, go to test
spray bar. step 3.
3. Check that indicator on right- If red indicator is in horizontal
side air valve is horizontal to position and problem still exists,
spray bar. go to test step 4.
4. Check for loose air a. If connections are okay, and
connections at right-side problem still exists, replace
spray valve. right-side spray valve, (TM
5-3800-205-23-3)
0005 00).
0007 00-41
TM 5-3800-205-23-1
5. No Pressure Discharge From Right Upper b. If problem still exists after

Spray Bar - Continued. adjustment, notify DS
control valve.
6. Pump Control Lever (Elevator Control Lever) 1. Check for bent or damaged a. If lever is bent or damaged,
Binds. lever. replace lever (WP 0114 00).

2.
2. Check elevator valve, inboard a. Clean debris from control

of left fender, for buildup of valve linkage.
debris.

test step 3.
3. Perform Main Control Valve a. Adjust relief valve setting.

Test and Adjustment (WP
0005 00).

control valve.
7. Pump Control Lever (Elevator Control Lever) Check for bent or damaged Replace bent or damaged
Will Not Engage. linkage. linkage (WP 0114 00).
8. Pump Control Lever (Elevator Control Lever) Check for bent or damaged Replace bent or damaged
Will Not Return to Hold Position. linkage. linkage (WP 0114 00).
9. Tank Cannot Be Filled Using Pressurized 1. Check that TANK FILL If switch is ON and problem still
Water Source Through Suction Inlet. SPARGER switch is ON. exists, notify DS Maintenance to
replace pump.

0005 00).

control valve.
10.Tank Cannot Be Suction Loaded Using 1. Check that locking lever If control lever is in FORWARD
Onboard Pump. (elevator direction control position and problem still exists,
lever) is in FORWARD replace vacuum generator (TM
position. 5-3800-205-23-3).
0007 00-42
TM 5-3800-205-23-1

10. Tank Cannot Be Suction Loaded Using 2. Perform Main Control Valve a. Adjust relief valve setting
Onboard Pump - Continued. Test and Adjustment (WP (WP 0005 00).
0005 00).
control valve.
11.Water Pump Will Not Operate in High Speed. 1. Check that pump control lever If control lever is in high speed
high speed position. go to test step 2.
NOTE
2. Check that red indicator on If red indicator is in horizontal
pump valve is horizontal to position and problem still exists,
suction pipe. go to test step 3.
3. Check for loose air If connections are okay, and
connections at pump valve. problem still exists, replace
pump valve (TM 5-3800-205-
23-3).
0005 00).
control valve.
12.Water Pump Will Not Operate in Low Speed. 1. Check that pump control lever If control lever is in low speed
low speed position. go to test step 2.
NOTE
2. Check that red indicator on If red indicator is in horizontal
pump valve is horizontal to position and problem still exists,
suction pipe. go to test step 3.
connections at pump valve. problem still exists, replace
pump valve (TM 5-3800-205-
23-3).
0007 00-43
TM 5-3800-205-23-1

13.Water Tank Drifts Up and Down When Tank 1. Check drift of tank hydraulic If drift exceeds 0.31 in. (7.9
Control Lever is in Hold Position. cylinders: mm), go to test step 2.
a. Lift water tank 6-10 in.
(15-25 cm).
b. Move control lever to hold
position.
c. After three (3) minutes,
make a mark on side of
tank at bottom of draft
arm. Mark should also be
6 in. (15 cm) from front of
water tank side.
d. After five (5) minutes,
make a measurement for
drift.
e. Drift on a new machine
should not be more than
0.31 in. (7.9 mm).
2. Check hydraulic cylinder(s) a. Repair any leaks if required.
for external leakage.
b. If cylinder(s) are damaged,
replace cylinder(s) (TM 5-
3800-205-23-3).
END OF WORK PACKAGE
0007 00-44
TM 5-3800-205-23-1
CHAPTER 3
UNIT MAINTENANCE PROCEDURES
TM 5-3800-205-23-1

TM 5-3800-205-23-1
SERVICE UPON RECEIPT 0008 00
GENERAL
1. When a new, used or reconditioned 613CS Scraper or 613CWD Water Distributor is first received, determine whether it
has been properly prepared for service and is in condition to perform its mission.
2. Follow the inspection and servicing instructions that follow.
INSPECTION INSTRUCTIONS
1. Read and follow all precautions and instructions on DD Form 1397.
2. Remove all packing and shipping material, such as tape, tie downs, protective covers, and shipping seals.
3. Inspect equipment for any damage incurred during shipment. Check if equipment has been modified.
4. Check equipment against packing slip to ensure that shipment is complete. Report any discrepancies on SF Form 364.
5. Remove all Basic Issue Item (BII), Additional Authorization List (AAL), and Components of End Item (COEI) equip-
ment and stow in accordance with TM 5-3800-205-10-1 or TM 5-3800-205-10-2.
SERVICING INSTRUCTIONS
1. Service the machine in accordance with TM 5-3800-205-10-1 or TM 5-3800-205-10-2 and Unit Preventive Mainte-
nance Checks and Service (PMCS) (WP 0009 00 and WP 0010 00). Schedule the next PMCS on DA Form 5986-E.
2. Refer to TM 5-3800-205-10-1 or TM 5-3800-205-10-2 and perform functional checks of all major machine systems.
END OF WORK PACKAGE
0008 00-1
TM 5-3800-205-23-1
0008 00-2
TM 5-3800-205-23-1
UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION 0009 00
GENERAL
1. To ensure that the 613CS Scraper and 613CWD Water Distributor are ready for operation at all times, they must be
lubricated and inspected on a regular basis so that defects may be found before they result in serious damage, equipment
failure or injury to personnel.
2. The KEY in this work package lists the types, amounts, and temperature ranges of the lubricants required for specified
intervals.
3. Lubrication Charts at the end of this work package show all lubrication points for the scraper and water distributor.
4. Table 1 in WP 0010 00 contains systematic instructions on lubrications, inspections, adjustments, and corrections to
be performed by Unit Maintenance to keep the 613CS Scraper in good operating condition and ready for its primary
mission.
5. Tables 2 through 7, located following scraper PMCS, list mandatory replacement parts, by interval, for the scraper.
NOTE
PMCS for the 613CWD Water Distributor begins on page 0009 00-43.
6. Table 8 in WP 0010 00 contains systematic instructions on lubrications, inspections, adjustments, and corrections to
be performed by Unit Maintenance to keep the 613CWD Water Distributor in good operating condition and ready
for its primary mission.
7. Tables 7 through 13, located following water distributor PMCS, list mandatory replacement parts, by interval, for
the water distributor.
8. For information on Corrosion Prevention and Control (CPC), refer to WP 0001 00.
EXPLANATION OF TABLE ENTRIES
1. Item Number (Item No.) Column. Numbers in this column are for reference. When completing DA Form 2404 or DA
Form 5988-E (Equipment Inspection and Maintenance Worksheet), include the item number for the check/service indi-
cating a fault. Item numbers also appear in the order you must perform checks and services for the interval listed.
NOTE
If both an hours and calendar interval are provided, perform check or service at whichever interval comes
first.
2. Interval Column. This column tells you when you must perform the procedure in the procedure column. Intervals are
based on calender dates or hours.
a. Hours procedures must be done at the hour interval listed.
b. Semiannual procedures must be done twice each year
c. Annual procedures must be done once each year.
d. Biennial procedures must be done once every two years.
3. Man-Hours Column. This column indicates man-hours required to complete prescribed lubrication service.
4. Item to Check/Service Column. This column identifies the item to be checked or serviced.
NOTE
The WARNINGs and CAUTIONs appearing in your PMCS table should always be observed. WARNINGs
and CAUTIONs appear before applicable procedures. These WARNINGs and CAUTIONs must be
observed to prevent serious injury to yourself and others or to prevent your equipment from being damaged.
5. Procedure Column. This column gives the procedure you must perform to check or service the item listed in the Item
to Check/Service column, to know if the equipment is ready or available for its intended mission or for operation. You
must perform the procedure at the time stated in the interval column.
0009 00-1
TM 5-3800-205-23-1
UNIT PREVENTIVE MAINTENANCE CHECKS AND

SERVICES (PMCS) INTRODUCTION - CONTINUED 0009 00
EXPLANATION OF TABLE ENTRIES - CONTINUED

6. Not Fully Mission Capable If: Column. Information in this column tells you what fault will keep your equipment from
being capable of performing its primary mission. If you perform check/service procedures that show faults listed in this
column, the equipment is not mission-capable. Follow standard operating procedures for maintaining the equipment or
reporting equipment failure.
GENERAL LUBRICATION PROCEDURES
NOTE
• Lubrication instructions contained in this PMCS are mandatory.
• Refer to TM 5-3800-205-10-1 or TM 5-3800-205-10-2 for Operator Maintenance level lubri-
cation.
• Dashed leader lines used in illustrations of lubrication points indicate that lubrication is
required on both sides of the equipment.
1. Recommended intervals are based on normal conditions of operation, temperature, and humidity. When operating under
extreme conditions, such as high or low temperatures or exposure to sand or dust, lubricants should always be changed
more frequently. Lubricants that have become contaminated must be changed regardless of interval. When in
doubt, notify your supervisor.
WARNING
When servicing this machine, performing maintenance, or disposing of materials such as engine coolant,
hydraulic fluid, lubricants, battery acids or batteries, and CARC paint, consult your unit/local hazardous
waste disposal center or safety office for local regulatory guidance. If further information is needed, please
contact The Army Environmental Hotline at 1-800-872-3845.
2. Ensure that all fluids drained as a result of lubrication or maintenance are collected in a suitable container and disposed
of in accordance with local policy and ordinances. Clean up any spills immediately.
3. Keep all lubricants in a closed container and store in a clean, dry place away from extreme heat. Keep container covers
clean and do not allow dust, dirt or other foreign material to mix with lubricants. Keep all lubrication equipment clean
and ready for use.
4. Maintain a good record of all lubrication performed and report any problem noted during lubrication. Refer to DA Pam
738-750 for maintenance forms and procedures to record and report any findings.
WARNING
However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-venti-
lated areas. Keep away from open flames and other sources of ignition. Failure to do so may result in
5. Keep all external parts of equipment not requiring lubrication free of lubricants. Before lubrication, wipe lubrication fit-
tings with a clean rag (Item 31, WP 0171 00) and solvent cleaning compound (Item 6, WP 0171 00). After lubrication,
wipe off excess oil or grease to prevent accumulation of foreign matter.
6. Refer to FM 9-207 for lubrication instructions in cold weather.
0009 00-2
TM 5-3800-205-23-1

GENERAL LUBRICATION PROCEDURES - CONTINUED

7. Refer to AR 70-12 for use of standardized fuels and lubricants.
8. Engine, transmission, and hydraulic system oil filters shall be changed when:
a. they are known to be contaminated or clogged;
b. at prescribed hardtime intervals.
9. This equipment is not covered by AOAP. Follow manufacturer’s intervals as specified in this manual.
10. For equipment under manufacturer’s warranty, hardtime oil service intervals shall be followed. Intervals shall be short-
ened if lubricants are known to be contaminated or if operation is under adverse conditions (i.e., longer-than-usual oper-
ating hours, extended idling periods or extreme dust).
GENERAL PMCS PROCEDURES
1. Always perform PMCS in the same order so it gets to be a habit. Once you’ve had some practice, you’ll spot anything
wrong in a hurry. If any deficiency is discovered, perform the appropriate troubleshooting task in Chapter 2 of this man-
ual. If any component or system is not serviceable, or if the given service does not correct the deficiency, notify your
supervisor.
2. Before performing preventive maintenance, read all the checks required for the applicable interval and prepare all tools
needed to make all checks. Have several clean rags (Item 31, WP 0171 00) handy. Perform ALL inspections at the appli-
cable interval.
a. Keep It Clean. Dirt, grease, oil, and debris get in the way and may cover up a serious problem. Clean as you work
and as needed. Use detergent (Item 11, WP 0171 00) and water when you clean.
b. Rust and Corrosion. Check metal parts for rust and corrosion. If any bare metal or corrosion exists, clean and
apply a light coat of lubricating oil (Item 24, WP 0171 00). Report it to your supervisor.
c. Bolts, Nuts, and Screws. Check bolts, nuts, and screws for obvious looseness, missing, bent or broken condition.
You can’t try them all with a tool, but look for chipped paint, bare metal or rust around bolt heads. If you find one
you think is loose, tighten it.
d. Welds. Look for loose or chipped paint, rust or gaps where parts are welded together. If you find a bad weld, report
it to your supervisor.
e. Electric Wires and Connectors. Look for cracked or broken insulation, bare wires, and loose or broken connec-
tors. Tighten loose connectors and ensure that the wires are in good condition.
f. Hydraulic Hoses and Lines. Look for wear, damage, and signs of leaks. Ensure that clamps and fittings are tight.
Wet spots indicate leaks, but a stain around a fitting or connector can also mean a leak. If a leak comes from a loose
fitting or connector, tighten it. If something is broken or worn out, correct it if authorized by the Maintenance Allo-
cation Chart (WP 0170 00). If not authorized, notify your supervisor.
g. Fluid Leakage. It is necessary for you to know how fluid leakage affects the status of your machine. The follow-
ing are definitions of the types/classes of leakage you need to know to be able to determine the status of your
machine. Learn and be familiar with them, and remember - when in doubt, notify your supervisor.
Leakage Definitions for PMCS
Class I Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops.
Class II Leakage of fluid great enough to form drops, but not enough to cause drops to drip from
item being checked/inspected.
Class III Leakage of fluid great enough to form drops that fall from item being checked/inspected.
0009 00-3
TM 5-3800-205-23-1

GENERAL PMCS PROCEDURES - CONTINUED
CAUTION
Operation is allowable with Class I and Class II leakage. WHEN IN DOUBT, NOTIFY YOUR SUPERVI-
SOR. When operating with Class I or Class II leaks, check fluid levels more frequently. Class III leaks must
be reported immediately to your supervisor. Failure to do this will result in damage to vehicle and/or compo-
nents.
PMCS INITIAL SETUP
1. General. This paragraph lists tools, materials, and personnel required for PMCS and lubrication.
2. Tools (WP 0172 00).
a. Common no. 1 shop set
b. Common no. 2 shop set
c. Drain tool
d. General mechanic’s tool kit
3. Materials (WP 0171 00).
a. Antifreeze
b. Brake fluid, automotive, silicone, MIL-B-46176
c. Cleaning compound, solvent
d. Cloth, abrasive, emery, fine
e. Detergent
f. Grease, GAA
g. Insulating varnish, electrical
h. Lubricating oil, OE/HDO 10
i. Lubricating oil, OE/HDO 10W/30
j. Lubricating oil, OE/HDO 15W/40
k. Lubricating oil, OE, HDO 30
l. Lubricating oil, OE HDO 40
m. Lubricating oil, OEA
n. Lubricating oil, GO 85W/140
o. Lubricating oil, GO 80W/90
p. Lubricating oil, GO 75
q. Petrolatum
r. Rags
4. Personnel.
a. Driver/Operator
b. Unit Maintenance Mechanic
0009 00-4
TM 5-3800-205-23-1
NOTE
• Components requiring lubrication on scraper only are identified by (S).
• Components requiring lubrication on water distributor only are identified by (WD).
- KEY -
EXPECTED TEMPERATURES*
-25°F to
LUBRICANT/ REFILL +6°F to +122°F -4°F to +50°F +32°F
COMPONENT CAPACITY (-14°C to +50°C) (-20°C to +10°C) (-4°C to 0°C) INTERVALS
OE/HDO HR - Hours
Lubricating Oil, ICE, Tac- S - Semiannual
tical A - Annual
B - Biennial
OEA
Lubricating Oil, ICE, Arc-
tic
7.8 Gal. See Chart A

Engine Crankcase
(30 L)
Oil Can Points As Reqd See Chart A
9.2 Gal. See Chart B

Transmission
(35 L)
24.5 Gal. (93 L) See Chart C

Hydraulic Tank
System Capacity
Water Pump Bearing As Reqd See Chart C

Housing (WD)
GO
Lubricating Oil, Gear,
Multipurpose
5 Gal. See Chart D
Front Axle Differential
(19 L)
1.5 Gal. See Chart D

Front Axle Final Drives
(6 L)
Elevator Speed 1.4 Gal. See Chart D

Reducer (S) (5 L)
BFS
Brake Fluid,
Automotive, Silicone
1.4 Pts. All Temperatures

Brake Fluid Reservoirs
(0.7 L)
GAA
Grease, Automotive and
Artillery
Wheel Bearings, Rear All Temperatures

Drive Shafts
Hitch
Steering Linkage
Tiedown D-Rings
Elevator Assembly (S)
Floor Rollers (S)
Ejector Rollers (S)
* For arctic operation, refer to FM 9-207.
0009 00-5
TM 5-3800-205-23-1
- KEY -
EXPECTED TEMPERATURES*
-25°F to
LUBRICANT/ REFILL +6°F to +122°F -4°F to +50°F +32°F
COMPONENT CAPACITY (-14°C to +50°C) (-20°C to +10°C) (-4°C to 0°C) INTERVALS
ANTIFREEZE HR - Hours
Ethylene Glycol, Inhib- S - Semiannual
ited, Heavy Duty A - Annual
B - Biennial
ANTIFREEZE
Ethylene Glycol, Arctic
Grade
9.9 Gal. (38 L) See Chart E

Engine Radiator
System Capacity
* For arctic operation, refer to FM 9-207.
0009 00-6
TM 5-3800-205-23-1
CHART A—ENGINE AND OIL CAN POINTS
EXPECTED TEMPERATURES
°F -70 -60 -50 -40 -30 -20 -10 0 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100 +120
Lubricant °C -57 -51 -46 -40 -34 -29 -23 -18 -12 -7 -1 +4 +10 +16 +21 +27 +32 +38 +49
OE/HDO Lubricating Oil, ICE,

Tactical
OEA Lubricating Oil, ICE,
Arctic
OE/HDO
15W/40
OE/HDO
10W/30
OEA
CHART B—TRANSMISSION
°F -70 -60 -50 -40 -30 -20 -10 0 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100 +120
Lubricant °C -57 -51 -46 -40 -34 -29 -23 -18 -12 -7 -1 +4 +10 +16 +21 +27 +32 +38 +49

Tactical
Arctic
OE/HDO 40
OE/HDO 30
OE/HDO 10*
OEA *
*If OEA lubricant is required to meet the low expected-temperature range, OEA lubricant is to be used in lieu of OE/HDO 10 lubricant for all
expected temperatures where OE/HDO 10 is specified.
CHART C—HYDRAULIC TANK AND WATER PUMP BEARING HOUSING (WD)
°F -70 -60 -50 -40 -30 -20 -10 0 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100 +120
Lubricant °C -57 -51 -46 -40 -34 -29 -23 -18 -12 -7 -1 +4 +10 +16 +21 +27 +32 +38 +49

Tactical
Arctic
OE/HDO 10*
OEA *
*If OEA lubricant is required to meet the low expected-temperature range, OEA lubricant is to be used in lieu of OE/HDO 10 lubricant for all
expected temperatures where OE/HDO 10 is specified.
0009 00-7
TM 5-3800-205-23-1
CHART D—FRONT AXLE DIFFERENTIAL AND FINAL DRIVES,

AND ELEVATOR SPEED REDUCER (S)
°F -90 -80 -70 -60 -50 -40 -30 -20 -10 0 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100 +120
Lubricant °C -68 -62 -57 -51 -46 -40 -34 -29 -23 -18 -12 -7 -1 +4 +10 +16 +21 +27 +32 +38 +49
GO Lubricating Oil, Gear,

Multipurpose
GO-75
GO-80W/90
GO-85W/140
CHART E—ANTIFREEZE
°F -90 -80 -70 -60 -50 -40 -30 -20 -10 0 +10 +20 +30 +40 +50 +60 +70 +80 +90 +100 +120
Lubricant °C -68 -62 -57 -51 -46 -40 -34 -29 -23 -18 -12 -7 -1 +4 +10 +16 +21 +27 +32 +38 +49
ANTIFREEZE Antifreeze, Ethylene

Glycol, Inhibited, Heavy
Duty
ANTIFREEZE Antifreeze, Arctic Grade
Antifreeze
Antifreeze,Arctic
Grade
0009 00-8
TM 5-3800-205-23-1
LUBRICANT • INTERVAL INTERVAL • LUBRICANT
250 OEA Engine Oil and

HR/A or Filter
Radiator Anti- B OE/ Replace
Drain/Refill freeze HDO
500 Secondary Fuel

HR/S Filters
Front Axle GO 250 Replace
Differential HR/S
Check Level 500 Hydraulic
and Add HR/S System Oil
Filters
Replace
Front Axle GO 250

Final Drives HR/S 250 BFS Brake Fluid
Check Level HR/S Reservoir
and Add Check Level
and Add
Transmission 1000
Oil Filter HR/A
Replace
Elevator Speed GO 250

Reducer HR/S
Check Level
and Add
500 Primary Fuel

HR/S Filter
Replace
Brake Fluid BFS 250

Reservoir HR/S
Check Level
and Add
613CS SCRAPER
0009 00-9
TM 5-3800-205-23-1
2000 OEA Hydraulic

HR/A or Tank
OE/ Drain and Refill
HDO
2000 GO Front Axle

Front Axle GO 2000 HR/A Final Drives
Differential HR/A Drain and Refill
Drain and Refill
1000 OEA Transmission

Upper and Lower GAA 250 HR/A or Drain and Refill
Drive Shafts HR/S OE/
3 Fittings HDO
2000 GAA Ejector Carrier

HR/A and Guide
Rollers
Pack
Elevator Speed GO 2000
Reducer HR/A
Drain and Refill
2000
HR/A GAA Wheel Bearings
Pack
613CS SCRAPER
0009 00-10
TM 5-3800-205-23-1
250 OEA Engine Oil and

HR/A or Filter
Radiator Anti- B OE/ Replace
Drain/Refill freeze HDO
500 Secondary Fuel

HR/S Filters
Front Axle GO 250 Replace
Differential HR/S
Check Level 500 Hydraulic
and Add HR/S System Oil
Filters
Replace
Front Axle GO
Final Drives 250 250 BFS Brake Fluid
Check Level HR/S HR/S Reservoir
and Add Check Level
and Add
Transmission 1000
Oil Filter HR/A
Replace
Water Pump OEA A

Bearing Housing or
Check Level OE/
and Add HDO
Water Pump OEA A

Bearing Housing or
Change Oil OE/
HDO
500 Primary Fuel
HR/S Filter
Replace
250 BFS Brake Fluid

HR/S Reservoir
Check Level
and Add
613CWD WATER DISTRIBUTOR
0009 00-11
TM 5-3800-205-23-1
2000 OEA Hydraulic

HR/A or Tank
OE/ Drain and Refill
HDO
2000 GO Front Axle

HR/A Final Drives
Front Axle GO 2000 Drain and Refill
Differential HR/A
Drain and Refill
1000 OEA Transmission
HR/A or Drain and Refill
Upper and Lower GAA 250 OE/
Drive Shafts HR/S HDO
3 Fittings
2000 GAA Wheel Bearings

HR/A Pack
613CWD WATER DISTRIBUTOR
END OF WORK PACKAGE
0009 00-12
TM 5-3800-205-23-1
UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) 0010 00
Table 1. Unit Preventive Maintenance Checks and

Services (PMCS) for 613CS Scraper.
LOCATION
ITEM TO
ITEM MAN- CHECK/ NOT FULLY MISSION
NO. INTERVAL HOURS SERVICE PROCEDURE CAPABLE IF:
WARNING
If machine is parked indoors during performance of PMCS,
DO NOT run engine unless exhaust fumes are vented to the
outside. Failure to follow this warning may cause injury or
death due to carbon monoxide poisoning.
NOTE
• Review all WARNINGs, CAUTIONs, and NOTEs before per-
forming PMCS on the 613CS Scraper.
• Unless otherwise indicated, perform all lubrication and pre-
ventive maintenance with machine parked on level ground,
parking brake applied, transmission in N (Neutral) and locked,
scraper bowl lowered to the ground, and engine shut down.
• Perform Operator PMCS prior to or in conjunction with Unit
PMCS if:
a. There is a delay between daily operation of the machine
and Unit PMCS.
b. The regular operator is not assisting.
0010 00-1
TM 5-3800-205-23-1
UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) - CONTINUED 0010 00

Services (PMCS) for 613CS Scraper - Continued.
LOCATION
ITEM TO
1 Initial 250 Transmis- NOTE

Hours sion
Transmission oil filter should be replaced after initial 250
hours of operation of a new or reconditioned machine.
Replace transmission oil filter (WP
0072 00) if machine is new or recondi-
tioned.
2 250 Hours 0.5 Hours Front Axle Check level of oil in each wheel end
or Semi- Final Drives final drive:
annual
a. Position front wheels with plug on
center line with front axle.
b. Clean area around plug.
c. Remove plug.
d. Maintain oil level to plug opening.
If level is low, add gear lubricating
oil (Item 21, 22, or 23, WP 0171
00).
e. Clean plug and install.
PLUG
0010 00-2
TM 5-3800-205-23-1

LOCATION
ITEM TO
3 250 Hours 0.2 Hours Front Axle Level check of oil in front axle differ-
or Semi- Differential ential:
annual
a. Clean area around level/fill plug,
located on front face of differential.
b. Remove level/fill plug.
c. Maintain oil level to level/fill plug
opening. If level is low, add gear
lubricating oil (Item 21, 22, or 23,
WP 0171 00).
d. Clean level/fill plug and install.
LEVEL/FILL
PLUG
FRONT AXLE
DIFFERENTIAL
4 250 Hours 0.6 Hours Brake Fluid CAUTION

or Semi- Reservoirs,
Use caution to ensure dirt and debris are not introduced into
annual Master Cyl-
reservoirs. Contamination of brake fluid could result.
inders,
Brake Lines, NOTE
and Fittings
• There is a brake fluid reservoir on both tractor and scraper. On
tractor, reservoir is located inboard of right fender. On scraper,
reservoir is located inside rear compartment.
• Scraper reservoir is illustrated.
a. Wipe cover of reservoir clean with
a clean rag (Item 31, WP 0171 00).
0010 00-3
TM 5-3800-205-23-1

LOCATION
ITEM TO
4 250 Hours 0.6 Hours Brake Fluid b. Release retainer and remove cover.
(Con’t) or Semi- Reservoirs, Clean diaphragm with a clean rag.
annual Master Cyl- Remove diaphragm.
inders, c. Brake fluid level should be 1/2 in.
Brake Lines, (13 mm) down from top of reser-
and Fittings voir. Add brake fluid (Item 4, WP
0171 00) as required.
d. Ensure diaphragm and cover are
clean. Install diaphragm and cover.
Secure cover with retainer.
RETAINER COVER BRAKE FLUID

RESERVOIR
DIAPHRAGM
390-012
0010 00-4
TM 5-3800-205-23-1

LOCATION
ITEM TO
4 250 Hours 0.6 Hours Brake Fluid NOTE

(Con’t) or Semi- Reservoirs,
• There is one brake master cylinder on scraper and two on trac-
annual Master Cyl-
tor.
inders,
Brake Lines, • Brake master cylinder on scraper is located inside rear com-
and Fittings partment.
• Brake master cylinders on tractor are located under tractor,
above right-rear corner of rear belly guard plate. One cylinder
is mounted laterally; the second one is above the first, mounted
longitudinally.
e. Inspect brake master cylinder(s),
brake lines, and fittings for leaks or
damage. Replace any damaged or
leaking component.
BRAKE BRAKE
BRAKE LINE MASTER CYLINDER BRAKE LINE MASTER CYLINDER
390-012 TRACTOR
SCRAPER
5 250 Hours Drive Belts a. Inspect drive belts for general con-
or Semi- dition: check for cracks, missing
annual pieces, frayed areas, and wear. A
worn belt will ride in the bottom of
the pulley or will be stretched
beyond limits of adjuster. Replace
worn or damaged belt (WP 0032
00).
0010 00-5
TM 5-3800-205-23-1

LOCATION
ITEM TO
5 250 Hours Drive Belts b. Check adjustment of drive belts: A

(Con’t) or Semi- correctly adjusted belt will deflect
annual 1/2-3/4 in. (13-19 mm) when a
deflection force of 25 lb (110 N) is
applied midway between pulleys.
Adjust belt tension as required (WP
0032 00).
6 250 Hours 0.2 Hours Elevator Check level of oil in elevator speed
or Semi- Speed reducer:
annual Reducer a. Clean area around level plug.
b. Remove level plug. Oil should drip
out of level plug opening.
c. If oil level is low, remove filler plug
and add gear lubricating oil (Item
21, 22 or 23, WP 0171 00) until oil
drips out level plug opening.
d. Clean filler and level plugs and
install.
LEVEL PLUG FILLER PLUG
0010 00-6
TM 5-3800-205-23-1

LOCATION
ITEM TO
7 250 Hours 0.3 Hours Drive Shafts a. Wipe grease fitting on upper drive
or Semi- shaft slip joint clean.
annual
b. Apply GAA grease (Item 16, WP
0171 00) to grease fitting.
GAA
0010 00-7
TM 5-3800-205-23-1

LOCATION
ITEM TO
7 250 Hours 0.3 Hours Drive Shafts c. Wipe grease fittings on lower drive
(Con’t) or Semi- shaft clean.
annual
d. Apply GAA grease (Item 16, WP
0171 00) to grease fittings.
GAA
8 250 Hours 0.6 Hours Engine Oil NOTE

or Semi- and Filter
• Machine should be parked on level ground, with transmission
annual
in Neutral (N) and locked with parking brake applied. Shut
down engine.
• Drain crankcase while oil is warm.
• Engine crankcase capacity is 7.8 gal. (30 L).
• Clean area around fill cap and drain plug prior to removing.
a. Remove engine oil fill cap inside
engine compartment.
b. Access oil pan by removing access
panel from middle guard plate
under tractor.
0010 00-8
TM 5-3800-205-23-1

LOCATION
ITEM TO
8 250 Hours 0.6 Hours Engine Oil c. Open draincock and drain oil into a
(Con’t) or Semi- and Filter suitable container. Dispose of
annual drained oil in accordance with local
policy and ordinances. Close drain-
cock and reinstall access panel to
middle guard plate.
DRAINCOCK
OIL PAN
0010 00-9
TM 5-3800-205-23-1

LOCATION
ITEM TO
8 250 Hours 0.6 Hours Engine Oil d. Replace engine oil filter (WP 0013
(Con’t) or Semi- and Filter 00).
annual
e. Add oil (Item 25, 26, or 29, WP
0171 00) through oil fill opening
until level on dipstick is between
ADD and FULL lines on dipstick.
ENGINE
OIL FILL
DIPSTICK
390-008
9 500 Hours Ejector Car- a. Check adjustment of ejector carrier

or Semi- rier (Lower) (lower) rollers. Adjust rollers as
annual and Ejector required (TM 5-3800-205-23-2).
Guide b. Check adjustment of ejector guide
(Upper) (upper) rollers. Adjust rollers as
Rollers required (TM 5-3800-205-23-2).
0010 00-10
TM 5-3800-205-23-1

Services (PMCS) for 613CS Scraper- Continued.
LOCATION
ITEM TO
10 500 Hours 0.6 Hours Fuel System

or Semi-
annual
WARNING
• DO NOT perform fuel system checks, inspections or mainte-
nance while smoking or near fire, flames or sparks. Fuel may
ignite, causing damage to machine and injury or death to per-
sonnel.
• Operating personnel must wear fuel-resistant gloves when han-
dling fuels. If exposed to fuel, promptly wash exposed skin and
change fuel-soaked clothing. Failure to do so may result in
injury to personnel
a. Replace fuel system primary and
secondary filters (TM 5-3800-205-
23-2 and WP 0021 00 of this man-
ual).
b. Disassemble and clean fuel tank
cap:
(1) Remove fuel tank cap.
(2) Remove gasket from cap and
inspect for damage. Replace
gasket if damaged.
WARNING
Solvent cleaning compound MIL-PRF-680 Type III is an
environmentally compliant and low toxic material. However,
it may be irritating to the eyes and skin. Use protective
gloves and goggles. Use in well-ventilated areas. Keep away
from open flames and other sources of ignition. Failure to do
so may result in injury or death to personnel.
(3) Disassemble fuel tank cap:
Remove valve assembly,
washer, baffle, gasket, and filter
elements.
0010 00-11
TM 5-3800-205-23-1

LOCATION
ITEM TO
10 500 Hours 0.6 Hours Fuel System (4) Clean elements in solvent
(Con’t) or Semi- cleaning compound (Item 6,
annual WP 0171 00). Inspect all parts
for damage and replace as
needed.
(5) Apply a thin coat of oil (Item
24, WP 0171 00) to filter ele-
ments and assemble cap.
Tighten valve assembly to 177
lb-in. (20 Nm). Install fuel cap
gasket.
GASKET VALVE ASSEMBLY VALVE

ASSEMBLY
FILTER
BAFFLE WASHER ELEMENTS
f. Remove strainer from filler neck of
fuel tank. Clean strainer in solvent
cleaning compound (Item 6, WP
0171 00).
g. Install strainer into filler neck.
Install fuel tank cap and tighten
securely.
11 500 Hours 1.0 Hours Hydraulic a. Replace hydraulic system oil filter
or Semi- System elements (WP 0115 00). Do NOT
annual change hydraulic system oil at this
time (Refer to Annual interval).
b. Clean hydraulic tank relief valve
(WP 0118 00).
0010 00-12
TM 5-3800-205-23-1

LOCATION
ITEM TO
12 Semiannual Draft Arm a. Check clearance between draft arm

Wear Plates shim and scraper bowl on each side
of bowl. Clearance should be 0.118
+/- 0.080 in. (3 +/- 2 mm).
b. If clearance is greater than 0.198 in.
(5 mm), add shim(s).
DRAFT ARM
SHIM
SCRAPER
BOWL
13 Semiannual Engine Open engine access door and access

Crankcase engine crankcase breather assembly
Breather on left side of engine compartment.
Assembly Clean breather:
a. Loosen clamp and remove hose
from cover of breather.
b. Remove bolt, washer, cover, and
breather element.
c. Inspect cover seal for damage.
Replace seal if damaged.
0010 00-13
TM 5-3800-205-23-1

LOCATION
ITEM TO
13 Semiannual Engine
(Con’t) Crankcase
Breather
Assembly
WARNING
• Solvent cleaning compound MIL-PRF-680 Type III is an envi-
ronmentally compliant and low toxic material. However, it may
be irritating to the eyes and skin. Use protective gloves and
goggles. Use in well-ventilated areas. Keep away from open
flames and other sources of ignition. Failure to do so may result
in injury or death to personnel.
• Compressed air used for cleaning or drying purposes, or for
clearing restrictions, should never exceed 30 psi (207 kPa). Use
protective equipment and exercise caution to avoid injury to
personnel.
d. Wash breather element in solvent
cleaning compound (Item 6, WP
0171 00). Shake dry or dry using
compressed air.
BOLT AND WASHER

CLAMP
HOSE
ELEMENT COVER
(HIDDEN)
e. Inspect hose and replace if dam-

aged.
0010 00-14
TM 5-3800-205-23-1

LOCATION
ITEM TO
13 Semiannual Engine f. Install breather element and cover

(Con’t) Crankcase with washer and bolt. Tighten bolt
Breather to 62 lb-in. (7 Nm).
Assembly g. Install hose to cover and tighten
clamp.
14 Semiannual Batteries
WARNING
• To avoid injury, eye protection and acid-resistant gloves must
be worn when working around batteries. Do not smoke, use
open flame, make sparks or create other ignition sources
around batteries. If a battery is giving off gases, it can explode
and cause injury to personnel. Remove all jewelry such as
rings, ID tags, watches, and bracelets. If jewelry or a tool con-
tacts a battery terminal, a direct short will result in instant heat-
ing, damage to equipment, and injury to personnel.
• Sulfuric acid contained in batteries can cause serious burns. If
battery corrosion or electrolyte makes contact with skin, eyes
or clothing, take immediate action to stop the corrosive burn-
ing effects. Failure to follow these procedures may result in
death or serious injury to personnel.
CAUTION
• If battery compartment is corroded, it will be necessary to
remove batteries and clean compartment to remove acid resi-
dues and corrosion.
• Buildup of dirt or corrosion on batteries may lead to electrical
malfunctions.
Service batteries as follows:
a. Access batteries inside engine air
filter and battery compartment.
b. Check battery hold-down for loose-
ness, corrosion or damage.
0010 00-15
TM 5-3800-205-23-1

LOCATION
ITEM TO
14 Semiannual Batteries c. Clean top of batteries with a clean

(Con’t) rag (Item 31, WP 0171 00).
d. Inspect batteries for evidence of a
cracked case and electrolyte leak-
age.
e. Disconnect battery cables (WP
0067 00).
NOTE
• If machine is equipped with original equipment maintenance-
free batteries, batteries will have no filler caps; electrolyte
level cannot be checked.
• Skip steps f through i if batteries are maintenance free.
f. Ensure all battery filler caps are
present.
g. Remove batteries (WP 0067 00).
h. Remove filler caps and check elec-
trolyte level in battery cells. Elec-
trolyte level should be to bottom of
filler openings. Add distilled water
as required and reinstall filler caps
snugly.
i. As required, use a baking soda
solution of 4 oz (100 grams) of bak-
ing soda with 1 qt (1 L) of clean
water to remove any acid film from
batteries. Rinse with clean water.
Reinstall batteries (WP 0067 00).
j. Clean battery terminals with a fine
grade of sandpaper or emery cloth
(Item 7, WP 0171 00).
k. Connect battery cables (WP 0067
00). Coat terminal connections with
petrolatum (Item 30, WP 0171 00).
0010 00-16
TM 5-3800-205-23-1

LOCATION
ITEM TO
15 Semiannual ROPS/FOPS a. Inspect for cracked welds, bends,

breaks, chipped/missing paint or
corrosion. Do NOT attempt to
straighten ROPS/FOPS or repair
welds. Replace ROPS/FOPS if
b. Check for loose or missing mount-
ing bolts, washers, and nuts. Install
new mounting hardware or tighten
as required. Apply torque of 317 lb-
ft (430 Nm).
16 Semiannual Seat Belt a. Inspect seat belt for security of
mounting, worn or frayed strap
webbing or worn or damaged
buckle and anticreep slides.
Replace seat belt if damaged (WP
0103 00).
NOTE
Date label attached to seat belt indicates age of belt.
b. Replace seat belt, regardless of con-
dition, if it has been in service for
three years (WP 0103 00).
17 Semiannual Electrical Inspect electrical ground connections
Ground on machine for secure connection and
Connections evidence of cracked insulating var-
nish. If connection is loose or there is
cracking in protective coating, discon-
nect connection, clean, thoroughly
dry, and reconnect. Apply insulating
varnish (Item 19, WP 0171 00) to con-
nection in accordance with manufac-
turer’s instructions on packaging.
0010 00-17
TM 5-3800-205-23-1

LOCATION
ITEM TO
18 Semiannual Wheels and a. Inspect tires for general condition

Tires and proper inflation of 45 psi (310
kPA). Replace any missing valve
stem caps.
b. Inspect tires for wear. If tread depth
is 0.39 in (10 mm) or less, or if
operator has reported a critical loss
of traction, replace tires (WP 0096
00 or TM 5-3800-205-23-2).
c. Check for loose or missing lug nuts.
Correct lug nut torque is 370 lb-ft
(500 Nm).
d. Inspect brake discs for excessive
scoring and pitting. Replace if
excessively scored or pitted (WP
0080 00 or TM 5-3800-205-23-2).
0010 00-18
TM 5-3800-205-23-1

LOCATION
ITEM TO
19 1000 Hours 1.2 Hours Transmis- NOTE

or Annual sion
down engine.
• Transmission fluid will drain easier if warm.
• Use a suitable container to catch transmission fluid. Transmis-
sion fluid capacity is 9.2 gal. (35 L).
a. Remove cap from transmission fill.
CAUTION
Install drain tool finger tight only until oil starts to drain. If
drain tool is forced into valve, damage to valve and leaking
will result.
b. Remove drain plug and O-ring
from transfer case. Insert drain tool
into drain valve and turn tool finger
tight to drain transmission fluid.
Dispose of fluid in accordance with
local policy and ordinances. Dis-
card O-ring. Clean drain plug and
reinstall, using a new O-ring.
0010 00-19
TM 5-3800-205-23-1

LOCATION
ITEM TO
19 1000 Hours 1.2 Hours Transmis-

(Con’t) or Annual sion
TRANSMISSION
FILL BREATHER
390-010 DRAIN PLUG TRANSFER

DIPSTICK AND O-RING CASE
c. Replace transmission oil filter (WP
0072 00).
d. Remove, clean, and reinstall trans-
mission oil suction screen and tube
assembly (magnetic screen) (WP
0074 00).
e. Remove, clean, dry, and reinstall
transmission breather.
f. Refill transmission with oil (Item
24, 27, 28, or 29, WP 0171 00)
through fill opening until reading
on dipstick is at COLD MIN SAFE
TO START with engine cold.
g. Start engine and bring transmission
to operating temperature. Fluid
level should be within cross-
hatched area, between ADD and
FULL marks on dipstick.
0010 00-20
TM 5-3800-205-23-1

LOCATION
ITEM TO
20 1000 Hours Engine Valve Notify DS Maintenance to check and

or Annual Lash Check adjust engine valve lash as required.
0010 00-21
TM 5-3800-205-23-1
0010 00-22
TM 5-3800-205-23-1

LOCATION
ITEM TO
21 2000 Hours 1.0 Hours Front Axle NOTE

or Annual Differential
• Front axle final drive capacity is 1.5 gal. (6 L).
and Final
Drives • Front axle differential capacity is 5 gal. (19 L).
• Clean area around fill and drain plugs prior to removing.
a. Park machine on level ground with
plugs at wheel end final drives ori-
ented at 6 o’clock. Remove plug,
O-ring, and seal at each wheel end
and drain oil into a suitable con-
tainer. Dispose of oil in accordance
with local policy and ordinances.
Discard plug O-ring and seal.
b. Remove level/fill plug and seal
from differential. Remove drain
plug and seal and drain oil. Discard
seals. Clean drain plug and reinstall
with a new seal.
LEVEL/FILL
PLUG AND
SEAL
DRAIN PLUG
AND SEAL
DIFFERENTIAL
0010 00-23
TM 5-3800-205-23-1

LOCATION
ITEM TO
21 2000 Hours 1.0 Hours Front Axle c. Position machine so that plugs at
(Con’t) or Annual Differential wheel end final drives are at 3 or 9
and Final o’clock.
Drives
PLUG WITH
O-RING AND SEAL FINAL
DRIVE
d. Add oil (Item 21, 22 or 23, WP

0171 00) to differential through
level/fill opening until oil is level
with opening. Clean level/fill plug
and reinstall with a new seal.
e. Add oil (Item 21, 22 or 23, WP
0171 00) at each wheel end until
level with opening. Clean plug and
reinstall with a new O-ring and
seal.
22 2000 Hours 4.0 Hours Rear Axle Notify DS Maintenance to remove,
or Annual Wheel Bear- clean, inspect, pack with GAA grease
ings (Item 16, WP 0171 00), and install
rear axle wheel bearings.
0010 00-24
TM 5-3800-205-23-1

LOCATION
ITEM TO
23 2000 Hours 1.0 Hours Hydraulic NOTE

or Annual System
• Hydraulic tank capacity is 24.5 gal (93 L).
• Perform service with machine on level ground, bowl lowered
and ejector moved all the way forward, transmission in Neutral
(N) and locked, parking brake applied, and engine shut down.
Oil should be warm.
• Clean area around fill cap and drain plug before removing.
a. Remove fill cap.
CAUTION
drain tool is forced into valve, damage to valve and leakage
will result.
from bottom of hydraulic tank.
Insert drain tool into drain valve
and turn tool finger tight to drain oil
into a suitable container. Dispose of
oil in accordance with local policy
and ordinances. Discard O-ring.
c. Clean drain plug and reinstall with
a new O-ring.
0010 00-25
TM 5-3800-205-23-1

LOCATION
ITEM TO
23 2000 Hours 1.0 Hours Hydraulic

(Con’t) or Annual System
HYDRAULIC
TANK
DRAIN PLUG
AND O-RING
d. Remove, clean, inspect, and rein-

stall relief valve (WP 0118 00).
e. Replace hydraulic system oil filters
(WP 0115 00).
f. Remove retaining ring and clean
strainer at fill opening. Reinstall
strainer.
g. Inspect fill cap gasket and replace if
damaged.
h. Fill tank with oil (Item 24 or 29,
WP 0171 00) until oil is visible in
sight gage. Install fill cap.
i. Start engine and bring hydraulic
system to operating temperature.
Oil level must be above bottom line
on sight gage. Add oil as required.
0010 00-26
TM 5-3800-205-23-1

LOCATION
ITEM TO
23 2000 Hours 1.0 Hours Hydraulic

(Con’t) or Annual System
OIL MUST
BE ABOVE
THIS LINE
390-009
24 2000 Hours 1.5 Hours Ejector Car- a. Remove, clean, inspect, and pack
or Annual rier (Lower) ejector carrier (lower) rollers with
Rollers grease (TM 5-3800-205-23-2).
b. Adjust ejector carrier rollers (TM
5-3800-205-23-2).
25 2000 Hours 1.5 Hours Ejector a. Remove, clean, inspect, and pack
or Annual Guide ejector guide (upper) rollers with
(Upper) grease (TM 5-3800-205-23-2).
Rollers
b. Adjust ejector guide (upper) rollers
(TM 5-3800-205-23-2).
0010 00-27
TM 5-3800-205-23-1

LOCATION
ITEM TO
26 2000 Hours Ejector Sup- a. Check clearance of two ejector sup-

or Annual port (Rear) port (rear) rollers at rear of ejector:
Rollers
(1) Move ejector all the way for-
ward. With ejector forward,
support rollers will be accessi-
ble inboard from rear tires.
(2) Measure clearance between
support roller and track on each
side of ejector frame. Clearance
should be 0.032-0.190 in. (0.80-
4.80 mm).
c. Check for wear or damage to sup-
port (rear) rollers.
d. If clearance is not as specified, or if
ejector support (rear) rollers are
worn or damaged, remove, clean,
inspect, and pack with grease or
replace rollers (TM 5-3800-205-23-
2).
EJECTOR
SUPPORT TRACK
(REAR)
ROLLER
0010 00-28
TM 5-3800-205-23-1

LOCATION
ITEM TO
27 2000 Hours 0.5 Hours Elevator NOTE

or Annual Speed
Refill capacity of elevator speed reducer is 10.6 qt (10 l).
Reducer
Change oil in elevator speed reducer:
a. Clean area around filler, level, and
drain plugs with a clean rag (Item
31, WP 0171 00).
b. Remove drain plug and allow oil to
drain into a suitable container. Dis-
pose of oil in accordance with local
policy and ordinances.
DRAIN
PLUG
390-1144
0010 00-29
TM 5-3800-205-23-1

LOCATION
ITEM TO
27 2000 Hours 0.5 Hours Elevator c. Clean drain plug and install.
(Con’t) or Annual Speed d. Remove level and filler plugs. Add
Reducer oil (Item 21, 22 or 23, WP 0171 00)
through filler plug opening until oil
drips out level plug opening.
e. Clean filler and level plugs and
install.
LEVEL PLUG FILLER PLUG
0010 00-30
TM 5-3800-205-23-1

LOCATION
ITEM TO
28 Annual Fuel Tank

Drain
WARNING
sonnel.
dling fuels. If exposed to fuel, promptly wash exposed skin
and change fuel-soaked clothing. Failure to do so may result in
injury to personnel. Failure to do so may result in injury to per-
sonnel.
Access fuel tank drain valve by open-
ing rear compartment access door at
rear of scraper. Attach a suitable drain
hose, open drain valve, and drain any
water/sediment from fuel tank into a
suitable container. Close drain valve
and remove drain hose.
FUEL TANK
DRAIN VALVE
390-012
0010 00-31
TM 5-3800-205-23-1

LOCATION
ITEM TO
29 Annual Brakes (All a. Inspect service brake pads for dam-

Wheels) age, wear, and loose mounting.
Measure thickness of lining. If less
than 0.50 in. (12.7 mm), replace
lining (WP 0084 00 or TM 5-3800-
205-23-2).
b. Inspect brake discs for distortion,
cracks, excessive scoring or wear.
Replace if damaged (WP 0080 00
or TM 5-3800-205-23-2).
c. Inspect brake fluid lines and fittings
for looseness, damage or leaks.
BRAKE FLUID
LINE
BRAKE
PAD
DISC FRONT AXLE
0010 00-32
TM 5-3800-205-23-1

LOCATION
ITEM TO
30 Annual Road Test a. Road test machine. Operate all

machine controls, check for proper
operation, and listen for abnormal
noise or vibrations.
b. Observe hitch area during road test
for play in hitch and steering link-
age. There should be no noticeable
play at hitch and steering linkage.
0010 00-33
TM 5-3800-205-23-1
0010 00-34
TM 5-3800-205-23-1

LOCATION
ITEM TO
31 Biennial Crankshaft a. Remove front guard plate under

Vibration tractor to access front of engine
Damper (WP 0100 00).
NOTE
Vibration damper has a weight located inside a silicone
fluid-filled case.
b. Inspect damper for dents, cracks or
evidence of leaks. If a fluid leak is
found, determine type of fluid. Sili-
cone fluid is transparent, viscous,
smooth, and difficult to remove
from surfaces. If leak is oil, crank-
shaft seals are suspect. Notify DS
Maintenance if damper is dented,
cracked or fluid leaks are evident.
VIBRATION DAMPER
0010 00-35
TM 5-3800-205-23-1

LOCATION
ITEM TO
32 Biennial 1.5 Hours Cooling Sys-

tem
WARNING
• DO NOT service cooling system unless engine has been
allowed to cool down. This is a pressurized cooling system and
escaping steam or hot coolant will cause serious burns.
• DO NOT remove cooling system radiator cap when engine is
hot. Allow engine to cool down. Failure to follow this warning
may cause serious burns.
• Wear effective eye, glove, and skin protection when handling
coolants. Failure to do so may cause injury.
NOTE
Cooling system capacity is 9.9 gal. (38 L).
a. Access engine compartment and
remove cooling system pressure
cap.
b. Attach a suitable drain hose to
draincock under right front of trac-
tor. Open draincock and drain cool-
ant into a suitable container.
Dispose of coolant in accordance
c. Flush cooling system with clean
water until draining water is clear.
d. Close draincock and remove drain
hose.
0010 00-36
TM 5-3800-205-23-1

LOCATION
ITEM TO

(Con’t) tem
RADIATOR
DRAINCOCK
e. Replace thermostat (WP 0028 00).

f. Add a 50/50 mixture of antifreeze
(Item 2 or 3, WP 0171 00) to radia-
tor. Leave radiator cap off.
g. Start engine and run until thermo-
stat opens and coolant level stabi-
lizes. Maintain level 1/2 in. (13
mm) from bottom of filler neck.
h. Inspect gasket of pressure cap and
replace if damaged. Install cap.
0010 00-37
TM 5-3800-205-23-1
Table 2. Scraper PMCS Mandatory Replacement Parts List - Initial 250 Hours.
ITEM PART
NO. NUMBER NSN NOMENCLATURE QTY
1 1R0719 2910-00-740-3593 Filter Element, Fluid Transmission 1

2 3J1907 5331-01-333-6444 O-ring 1
3 2S8439 5330-01-021-9880 Seal 1
Table 3. Scraper PMCS Mandatory Replacement Parts List - 250 Hours or Annual.
ITEM PART
1 1R0739 2940-00-029-0388 Filter Element, Fluid, Engine 1
Table 4. Scraper PMCS Mandatory Replacement Parts List - 500 Hours or Semiannual.
ITEM PART
1 1R0751 2910-01-424-7315 Filter Element, Fluid, Secondary Fuel Filter 2

2 117-4089 2910-01-443-6227 Filter Element, Fluid, Fuel/Water Separator 1
3 1328879 4330-01-509-0939 Filter Element, Fluid Hydraulic System 2
Table 5. Scraper PMCS Mandatory Replacement Parts List - 1000 Hours or Semiannual.
ITEM PART
1 1R0719 2910-00-740-3593 Filter Element, Fluid, Transmission (Annual) 1

2 3J1907 5331-01-333-6444 O-ring 1
3 5H7521 5331-00-555-3810 O-ring, Transmission Oil Section Screen Cover 1
4 2S8439 5330-01-021-9880 Seal 1
Table 6. Scraper PMCS Mandatory Replacement Parts List - 2000 Hours or Annual.
ITEM PART
1 1328876 4330-01-509-0939 Filter Element, Fluid, Hydraulic System 2

2 2S4663 5330-00-470-5727 Gasket, Valve Safety Relief 2
3 5H2767 5331-00-850-7586 O-ring, Front Axle Final Drive 2
4 5M2057 5331-00-855-8047 O-ring, Hydraulic Tank 1
5 3J1907 5331-01-333-6444 O-ring, Valve, Safety Relief 1
6 5P8132 5325-01-185-7726 Ring, Retaining 1
0010 00-38
TM 5-3800-205-23-1
Table 7. Scraper PMCS Mandatory Replacement Parts List - Biennial.
ITEM PART
1 195-7339 5330-01-508-2775 Gasket, Thermostat 1

2 126-5869 6685-01-474-2254 Thermostat 1
0010 00-39
TM 5-3800-205-23-1
0010 00-40
TM 5-3800-205-23-1

Services (PMCS) for 613CWD Water Distributor.
LOCATION
ITEM TO
WARNING
If machine is parked indoors during performance of PMCS,
DO NOT run engine unless exhaust fumes are vented to the
outside. Failure to follow this warning may cause injury or
death due to carbon monoxide poisoning.
NOTE
• Review all WARNINGs, CAUTIONs, and NOTEs before per-
forming PMCS on the 613CWD Water Distributor.
• Unless otherwise indicated, perform all lubrication and pre-
ventive maintenance with machine parked on level ground,
parking brake applied, transmission in N (Neutral) and locked,
scraper bowl lowered to the ground, and engine shut down.
• Perform Operator PMCS prior to or in conjunction with Unit
PMCS if:
a. There is a delay between daily operation of the machine
and Unit PMCS.
b. The regular operator is not assisting.
0010 00-41
TM 5-3800-205-23-1
0010 00-42
TM 5-3800-205-23-1

Services (PMCS) for 613CWD Water Distributor - Continued.
LOCATION
ITEM TO
1 Initial 250 Transmis- NOTE
Hours sion Transmission oil filter should be replaced after initial 250
hours of operation of a new or reconditioned machine.
Replace transmission oil filter (WP
0072 00) if machine is new or recondi-
tioned.
2 250 Hours 0.5 Hours Front Axle Check level of oil in each wheel end
or Semi- Final Drives final drive:
annual
a. Position front wheels with plug on
center line with front axle.
b. Clean area around plug.
c. Remove plug.
d. Maintain oil level to plug opening.
If level is low, add gear lubricating
oil (Item 21, 22 or 23, WP 0171
00).
e. Clean plug and install.
PLUG
3 250 Hours 0.2 Hours Front Axle Level check of oil in front axle differ-
or Semi- Differential ential:
annual a. Clean area around level/fill plug,
located on front face of differential.
b. Remove level/fill plug.
0010 00-43
TM 5-3800-205-23-1

LOCATION
ITEM TO
3 250 Hours 0.2 Hours Front Axle c. Maintain oil level to level/fill plug
(Con’t) or Semi- Differential opening. If level is low, add gear
annual lubricating oil (Item 21, 22 or 23,
WP 0171 00).
d. Clean level/fill plug and install.
LEVEL/FILL
PLUG
FRONT AXLE
DIFFERENTIAL
4 250 Hours 0.6 Hours Brake Fluid CAUTION

or Semi- Reservoirs,
Use caution to ensure dirt and debris are not introduced into
annual Master Cyl-
reservoirs. Contamination of brake fluid could result.
inders,
Brake Lines, NOTE
and Fittings • There is a brake fluid reservoir on both tractor and water dis-
tributor. On tractor, reservoir is located inboard of right fender.
On water distributor, reservoir is located under water distribu-
tor rear steps.
• Water distributor reservoir is illustrated.
a. Wipe cover of reservoir clean with
a clean rag (Item 31, WP 0171 00).
b. Release retainer and remove cover.
Clean diaphragm with a clean rag.
Remove diaphragm.
0010 00-44
TM 5-3800-205-23-1

LOCATION
ITEM TO
4 250 Hours 0.6 Hours Brake Fluid c. Brake fluid level should be 1/2 in.
(Con’t) or Semi- Reservoirs, (13 mm) down from top of reser-
annual Master Cyl- voir. Add brake fluid (Item 4, WP
inders, 0171 00) as required.
Brake Lines, d. Ensure diaphragm and cover are
and Fittings clean. Install diaphragm and cover.
Secure cover with retainer.
COVER RETAINER DIAPHRAGM
BRAKE FLUID
RESERVOIR
NOTE
• There is one brake master cylinder on water distributor and
two on tractor.
• Brake master cylinder on water distributor is located under rear
steps.
• Brake master cylinders on tractor are located under tractor,
above right-rear corner of rear belly guard plate. One cylinder
is mounted laterally; the second one is above the first, mounted
longitudinally.
0010 00-45
TM 5-3800-205-23-1

LOCATION
ITEM TO
4 250 Hours 0.6 Hours Brake Fluid Inspect brake master cylinder(s),
(Con’t) or Semi- Reservoirs, brake lines, and fittings for leaks or
annual Master Cyl- damage. Replace any damaged or
inders, leaking component.
Brake Lines,
and Fittings
BRAKE BRAKE
LINE MASTER CYLINDER
BRAKE LINES
BRAKE
MASTER
CYLINDER
WATER DISTRIBUTOR TRACTOR
5 250 Hours Drive Belts a. Inspect drive belts for general con-
or Semi- dition: check for cracks, missing
annual pieces, frayed areas, and wear. A
worn belt will ride in the bottom of
the pulley or will be stretched
beyond limits of adjuster. Replace
worn or damaged belt (WP 0032
00).
b. Check adjustment of drive belts: A
correctly adjusted belt will deflect
1/2-3/4 in. (13-19 mm) when a
deflection force of 25 lb (110 N) is
applied midway between pulleys.
Adjust belt tension as required (WP
0032 00).
0010 00-46
TM 5-3800-205-23-1

LOCATION
ITEM TO
6 250 Hours 0.3 Hours Drive Shafts a. Wipe grease fitting on upper drive
or Semi- shaft slip joint clean.
annual
b. Apply GAA grease (Item 16, WP
GAA
c. Wipe grease fittings on lower drive

shaft clean.
d. Apply GAA grease (Item 16, WP
GAA
GAA
0010 00-47
TM 5-3800-205-23-1

LOCATION
ITEM TO
7 250 Hours 0.6 Hours Engine Oil NOTE

or Semi- and Filter
annual
in Neutral (N) and locked and parking brake applied. Shut
down engine.
• Drain crankcase while oil is warm.
• Engine crankcase capacity is 7.8 gal. (30 L).
a. Remove engine oil fill cap inside
engine compartment.
b. Access oil pan by removing access
panel from middle guard plate
under tractor.
c. Open draincock and drain oil into a
suitable container. Dispose of
drained oil in accordance with local
policy and ordinances. Close drain-
cock and reinstall access panel to
middle guard plate.
DRAINCOCK
OIL PAN
d. Replace engine oil filter (WP 0013

00).
0010 00-48
TM 5-3800-205-23-1

LOCATION
ITEM TO
8 500 Hours 0.6 Hours Fuel System

or Semi-
annual
WARNING
sonnel.
dling fuels. If exposed to fuel, promptly wash exposed skin and
change fuel-soaked clothing.
a. Replace fuel system primary and
secondary filters (TM 5-3800-205-
23-3 and WP 0021 00 of this man-
ual).
b. Disassemble and clean fuel tank
cap:
(1) Remove fuel tank cap.
(2) Remove gasket from cap and
inspect for damage. Replace
gasket if damaged.
WARNING
Solvent cleaning compound MIL-PRF-680 Type III is an
environmentally compliant and low toxic material. However,
it may be irritating to the eyes and skin. Use protective
gloves and goggles. Use in well-ventilated areas. Keep away
from open flames and other sources of ignition. Failure to do
so may result in injury or death to personnel.
(3) Disassemble fuel tank cap:
Remove valve assembly,
washer, baffle, gasket, and filter
elements.
0010 00-49
TM 5-3800-205-23-1

LOCATION
ITEM TO
8 500 Hours 0.6 Hours Fuel System (4) Clean elements in solvent
(Con’t) or Semi- cleaning compound (Item 6,
annual WP 0171 00). Inspect all parts
for damage and replace as
needed.
(5) Apply a thin coat of oil (Item
24, WP 0171 00) to filter ele-
ments and assemble cap.
Tighten valve assembly to 177
lb-in. (20 Nm). Install fuel cap
gasket.
GASKET VALVE ASSEMBLY VALVE

ASSEMBLY
FILTER FILTER
BAFFLE WASHER
ELEMENTS ELEMENTS
f. Remove strainer from filler neck of
fuel tank. Clean strainer in dry
cleaning solvent (Item 6, WP 0171
00).
g. Install strainer into filler neck.
Install fuel tank cap and tighten
securely.
9 500 Hours 1.0 Hours Hydraulic a. Replace hydraulic system oil filter
or Semi- System elements (WP 0115 00). Do NOT
annual change hydraulic system oil at this
time (Refer to Annual interval).
b. Clean hydraulic tank relief valve
(WP 0118 00).
0010 00-50
TM 5-3800-205-23-1

LOCATION
ITEM TO
10 Semiannual Engine Open engine access door and access

Crankcase engine crankcase breather assembly
Breather on left side of engine compartment.
Assembly Clean breather:
a. Loosen clamp and remove hose
from cover of breather.
b. Remove bolt, washer, cover, and
breather element.
c. Inspect cover seal for damage.
Replace seal if damaged.
WARNING
• Solvent cleaning compound, MIL-PRF-680 Type III is an envi-
ronmentally compliant and low toxic material. However, it may
be irritating to the eyes and skin. Use protective gloves and
goggles. Use in well-ventilated areas. Keep away from open
flames and other sources of ignition. Failure to do so may result
in injury or death to personnel.
• Compressed air used for cleaning or drying purposes, or for
clearing restrictions, should never exceed 30 psi (207 kPa). Use
protective equipment and exercise caution to avoid injury to
personnel.
0010 00-51
TM 5-3800-205-23-1

LOCATION
ITEM TO
10 Semiannual Engine d. Wash breather element in solvent

(Con’t) Crankcase cleaning compound (Item 6, WP
Breather 0171 00). Shake dry or dry using
Assembly compressed air.
e. Inspect hose and replace if dam-
aged.
f. Install breather element and cover
with washer and bolt. Tighten bolt
to 62 lb-in (7 Nm).
g. Install hose to cover and tighten
clamp.
BOLT AND WASHER
CLAMP
HOSE COVER
0010 00-52
TM 5-3800-205-23-1

LOCATION
ITEM TO
11 Semiannual Batteries
WARNING
• To avoid injury, eye protection and acid-resistant gloves must
be worn when working around batteries. Do not smoke, use
open flame, make sparks or create other ignition sources
around batteries. If a battery is giving off gases, it can explode
and cause injury to personnel. Remove all jewelry such as
rings, ID tags, watches, and bracelets. If jewelry or a tool con-
tacts a battery terminal, a direct short will result in instant heat-
ing, damage to equipment, and injury to personnel.
• Sulfuric acid contained in batteries can cause serious burns. If
battery corrosion or electrolyte makes contact with skin, eyes
or clothing, take immediate action to stop the corrosive burn-
ing effects. Failure to follow these procedures may result in
death or serious injury to personnel.
CAUTION
• If battery compartment is corroded, it will be necessary to
remove batteries and clean compartment to remove acid resi-
dues and corrosion.
• Buildup of dirt or corrosion on batteries may lead to electrical
malfunctions.
Service batteries as follows:
a. Access batteries inside engine air
filter and battery compartment.
b. Check battery hold-down for loose-
ness, corrosion or damage.
c. Clean top of batteries with a clean
rag (Item 31, WP 0171 00).
d. Inspect batteries for evidence of a
cracked case and electrolyte leak-
age.
e. Disconnect battery cables (WP
0067 00).
0010 00-53
TM 5-3800-205-23-1

LOCATION
ITEM TO
11 Semiannual Batteries NOTE

(Con’t)
• If machine is equipped with original equipment maintenance-
free batteries, batteries will have no filler caps; electrolyte
level cannot be checked.
• Skip steps f through i if batteries are maintenance free.
f. Ensure all battery filler caps are
present.
g. Remove batteries (WP 0067 00).
h. Remove filler caps and check elec-
trolyte level in battery cells. Elec-
trolyte level should be to bottom of
filler openings. Add distilled water
as required and reinstall filler caps
snugly.
i. As required, use a baking soda
solution of 4 oz (100 grams) of bak-
ing soda with 1 qt (1 L) of clean
water to remove any acid film from
batteries. Rinse with clean water.
Reinstall batteries (WP 0067 00).
j. Clean battery terminals with a fine
grade of sandpaper or emery cloth
(Item 7, WP 0171 00).
k. Connect battery cables (WP 0067
00). Coat terminal connections with
petrolatum (Item 30, WP 0171 00).
0010 00-54
TM 5-3800-205-23-1

LOCATION
ITEM TO
12 Semiannual ROPS/FOPS a. Inspect for cracked welds, bends,

breaks, chipped/missing paint or
corrosion. Do NOT attempt to
straighten ROPS/FOPS or repair
welds. Replace ROPS/FOPS if
b. Check for loose or missing mount-
ing bolts, washers, and nuts. Install
new mounting hardware or tighten
as required. Apply torque of 317 lb-
ft (430 Nm).
13 Semiannual Seat Belt a. Inspect seat belt for security of
mounting, worn or frayed strap
webbing or worn or damaged
buckle and anticreep slides.
Replace seat belt if damaged (WP
0104 00).
NOTE
Date label attached to seat belt indicates age of belt.
b. Replace seat belt, regardless of con-
dition, if it has been in service for
three years (WP 0104 00).
14 Semiannual Electrical Inspect electrical ground connections
Ground on machine for secure connection and
Connections evidence of cracked insulating var-
nish. If connection is loose or there is
cracking in protective coating, discon-
nect connection, clean, thoroughly
dry, and reconnect. Apply insulating
varnish (Item 19, WP 0171 00) to con-
nection in accordance with manufac-
turer’s instructions on packaging.
0010 00-55
TM 5-3800-205-23-1

LOCATION
ITEM TO
15 Semiannual Wheels and a. Inspect tires for general condition

Tires and proper inflation of 45 psi (310
kPa). Replace any missing valve
stem caps.
b. Inspect tires for wear. If tread depth
is 10 mm (0.39 in.) or less, or if
operator has reported a critical loss
of traction, replace tires (WP 0096
00 or TM 5-3800-205-23-2).
c. Check for loose or missing lug nuts.
Correct lug nut torque is 370 lb-ft
(500 Nm).
d. Inspect brake discs for excessive
scoring and pitting. Replace if
excessively scored or pitted (WP
0080 00 or TM 5-3800-205-23-2).
16 Semiannual 0.3 Hours Water Pump Check level of oil in bearing housing
Bearing of water pump:
Housing
a. Access water pump under steps at
rear of water distributor.
b. Clean area around level and filler
plugs with a clean rag (Item 31, WP
0171 00).
c. Remove level plug. Oil should be
level with plug.
d. If level is low, remove filler plug
and add oil (Item 24 or 29, WP
0171 00) until drainage is noted
from level plug. Clean level and
filler plugs and install.
0010 00-56
TM 5-3800-205-23-1

LOCATION
ITEM TO
16 Semiannual 0.3 Hours Water Pump

(Con’t) Bearing
Housing
FILLER PLUG
LEVEL PLUG
WATER PUMP
BEARING
HOUSING
0010 00-57
TM 5-3800-205-23-1
0010 00-58
TM 5-3800-205-23-1

LOCATION
ITEM TO
17 1000 Hours 1.0 Hours Transmis- NOTE

or Annual sion
down engine.
• Transmission fluid will drain easier if warm.
• Transmission fluid capacity is 9.2 gal. (35 L).
a. Remove cap from transmission fill.
CAUTION
will result.
0010 00-59
TM 5-3800-205-23-1

LOCATION
ITEM TO
17 1000 Hours 1.0 Hours Transmis- b. Remove drain plug and O-ring
(Con’t) or Annual sion from transfer case. Insert drain tool
into drain valve and turn tool finger
tight to drain transmission fluid into
a suitable container. Dispose of
fluid in accordance with local pol-
icy and ordinances. Discard O-ring.
Clean drain plug and reinstall,
using a new O-ring.
TRANSMISSION
FILL BREATHER
390-010 DRAIN PLUG TRANSFER

DIPSTICK AND O-RING CASE
c. Replace transmission oil filter (WP
0072 00).
d. Remove, clean, and reinstall trans-
mission oil suction screen and tube
assembly (magnetic screen) (WP
0074 00).
e. Remove, clean, dry, and reinstall
transmission breather.
0010 00-60
TM 5-3800-205-23-1

LOCATION
ITEM TO
17 1000 Hours 1.0 Hours Transmis- f. Refill transmission with oil (Item
(Con’t) or Annual sion 24, 27, 28 or 29, WP 0171 00)
through fill opening until reading
on dipstick is at COLD MIN SAFE
TO START with engine cold.
g. Start engine and bring transmission
to operating temperature. Fluid
level should be within cross-
hatched area, between ADD and
FULL marks on dipstick.
18 1000 Hours Engine Valve Notify DS Maintenance to check and
or Annual Lash Check adjust engine valve lash as required.
0010 00-61
TM 5-3800-205-23-1
0010 00-62
TM 5-3800-205-23-1

LOCATION
ITEM TO
19 2000 Hours 1.0 Hours Front Axle NOTE

or Annual Differential
• Front axle final drive capacity is 1.5 gal. (6 L).
and Final
Drives • Front axle differential capacity is 5 gal. (19 L).
• Clean area around fill and drain plugs prior to removing.
a. Park machine on level ground with
plugs at wheel end final drives ori-
ented at 6 o’clock. Remove plug,
O-ring, and seal at each wheel end
and drain oil into a suitable con-
tainer. Dispose of oil in accordance
Discard plug O-ring and seal.
b. Remove level/fill plug from differ-
ential. Remove drain plug and seal
and drain oil. Discard seals. Clean
drain plug and reinstall with a new
seal.
LEVEL/FILL
PLUG AND
SEAL
DRAIN PLUG
AND SEAL
DIFFERENTIAL
0010 00-63
TM 5-3800-205-23-1

LOCATION
ITEM TO
19 2000 Hours 1.0 Hours Front Axle c. Position machine so that plugs at
(Con’t) or Annual Differential wheel end final drives are at 3 or 9
and Final o’clock.
Drives
PLUG WITH
O-RING AND SEAL FINAL
DRIVE
d. Add oil (Item 21, 22 or 23, WP

0171 00) to differential through
level/fill opening until oil is level
with opening. Clean level/fill plug
and reinstall with a new seal.
e. Add oil (Item 21, 22 or 23, WP
0171 00) at each wheel end until
level with opening. Clean plug and
reinstall with a new O-ring and
seal.
20 2000 Hours 4.0 Hours Rear Axle Notify DS Maintenance to remove,
or Annual Wheel Bear- clean, inspect, pack with GAA grease
ings (Item 16, WP 0171 00), and install
rear axle wheel bearings (TM 5-3800-
205-23-3).
0010 00-64
TM 5-3800-205-23-1

LOCATION
ITEM TO
21 2000 Hours 1.0 Hours Hydraulic NOTE

or Annual System • Hydraulic tank capacity is 24.5 gal (93 L).
• Perform service with machine on level ground, tank lowered,
transmission in Neutral (N) and locked, parking brake applied,
and engine shut down. Oil should be warm.
• Clean area around fill cap and drain plug before removing.
a. Remove fill cap.
CAUTION
will result.
from bottom of hydraulic tank.
Insert drain tool into drain valve
and turn tool finger tight to drain oil
into a suitable container. Dispose of
oil in accordance with local policy
and ordinances. Discard O-ring.
c. Clean drain plug and reinstall with
a new O-ring.
HYDRAULIC
TANK
DRAIN PLUG
AND O-RING
0010 00-65
TM 5-3800-205-23-1

LOCATION
ITEM TO
21 2000 Hours 1.0 Hours Hydraulic d. Remove, clean, inspect, and rein-
(Con’t) or Annual System stall relief valve (WP 0118 00).
e. Replace hydraulic system oil filters
(WP 0115 00).
f. Remove retaining ring and clean
strainer at fill opening. Reinstall
strainer.
g. Inspect fill cap gasket and replace if
damaged.
h. Fill tank with oil (Item 24 or 29,
WP 0171 00) until oil is visible in
sight gage. Install fill cap.
i. Start engine and bring hydraulic
system to operating temperature.
Oil level must be above bottom line
on sight gage. Add oil as required.
OIL MUST
BE ABOVE
THIS LINE
0010 00-66
TM 5-3800-205-23-1

LOCATION
ITEM TO
22 Annual Road Test a. Road test machine. Operate all

machine controls, check for proper
operation, and listen for abnormal
noise or vibrations.
b. Observe hitch area during road test
for play in hitch and steering link-
age. There should be no noticeable
play at hitch and steering linkage.
23 Annual Fuel Tank
Drain
WARNING
ignite, causing damage to vehicle and injury or death to per-
sonnel.
dling fuels. If exposed to fuel, promptly wash exposed skin
and change fuel-soaked clothing. Failure to do so may result in
Access fuel tank drain valve inboard
of right-rear tire. Attach a suitable
drain hose, open drain valve, and drain
any water/sediment from fuel tank
into a suitable container. Close drain
valve and remove drain hose.
0010 00-67
TM 5-3800-205-23-1

LOCATION
ITEM TO
24 Annual Brakes (All a. Inspect service brake pads for dam-

Wheels) age, wear, and loose mounting.
Measure thickness of lining. If less
than 0.50 in. (12.7 mm), replace
lining (WP 0084 00 or TM 5-3800-
205-23-3).
b. Inspect brake discs for distortion,
cracks, excessive scoring or wear.
Replace if damaged (WP 0080 00
or TM 5-3800-205-23-3).
c. Inspect brake fluid lines and fittings
for looseness, damage or leaks.
BRAKE FLUID LINE
BRAKE
PAD
FRONT AXLE
DISC
0010 00-68
TM 5-3800-205-23-1

LOCATION
ITEM TO
25 Annual 0.5 Hours Water Pump Change oil in water pump bearing
Bearing housing:
Housing a. Access water pump under steps at
rear of water distributor.
b. Clean area around drain, level, and
filler plugs with a clean rag (Item
31, WP 0171 00).
c. Remove drain plug and allow oil to
drain into a suitable container. Dis-
pose of oil in accordance with local
policy and ordinances.
FILLER PLUG
LEVEL
PLUG
WATER PUMP BEARING HOUSING DRAIN PLUG
d. Clean drain plug and install.

e. Remove level and filler plugs.
f. Add oil (Item 24 or 29, WP 0171
00) until drainage is noted from
level plug. Clean level and filler
plugs and install.
0010 00-69
TM 5-3800-205-23-1

LOCATION
ITEM TO
26 Annual Foot Valve Remove foot valve access plate and

Assembly clean debris from foot valve screen.
Reinstall plate (TM 5-3800-205-23-
3).
27 Annual Water Dis- a. Remove, clean, and reinstall the
tributor following drain plugs: front tank
Tank drain, upper spray bar drain, and
water pump housing drain.
b. Inspect can breaker/bag cutter com-
ponents at tank rear access opening
for corrosion, looseness or other
damage. Replace any damaged
component (TM 5-3800-205-23-3).
c. Inspect front inspection cover and
rear access opening for corrosion or
damage. Replace any damaged
component (TM 5-3800-205-23-3).
28 Annual Upper Spray Inspect spray heads for corrosion,
Bar Spray looseness or damage. Replace any
Heads damaged component (TM 5-3800-
205-23-3).
29 Annual Lower Spray Inspect nozzles on lower spray bar and
Bar and De- de-icing extensions for corrosion,
icing Exten- looseness or damage. Replace any
sion Nozzles damaged nozzle (TM 5-3800-205-23-
3).
0010 00-70
TM 5-3800-205-23-1

LOCATION
ITEM TO
30 Biennial Crankshaft a. Remove front guard parts under

Vibration tractor to access front of engine
Damper (WP 0100 00).
NOTE
Vibration damper has a weight located inside a silicone
fluid-filled case.
b. Inspect damper for dents, cracks or
evidence of leaks. If a fluid leak is
found, determine type of fluid. Sili-
cone fluid is transparent, viscous,
smooth, and difficult to remove
from surfaces. If leak is oil, crank-
shaft seals are suspect. Notify DS
Maintenance if damper is dented,
cracked or fluid leaks are evident.
VIBRATION DAMPER
0010 00-71
TM 5-3800-205-23-1

LOCATION
ITEM TO

tem
WARNING
• DO NOT service cooling system unless engine has been
allowed to cool down. This is a pressurized cooling system and
escaping steam or hot coolant will cause serious burns.
• DO NOT remove cooling system radiator cap when engine is
hot. Allow engine to cool down. Failure to follow this warning
• Wear effective eye, glove, and skin protection when handling
coolants. Failure to do so may cause injury.
NOTE
Cooling system capacity is 9.9 gal. (38 L).
a. Access engine compartment and
remove cooling system pressure
cap.
b. Attach a suitable drain hose to
draincock under right front of trac-
tor. Open draincock and drain cool-
ant into a suitable container.
Dispose of coolant in accordance
c. Flush cooling system with clean
water until draining water is clear.
d. Close draincock and remove drain
hose.
0010 00-72
TM 5-3800-205-23-1

Services (PMCS) for 613CWD Water Distributor- Continued.
LOCATION
ITEM TO

(Con’t) tem
RADIATOR
DRAINCOCK
e. Replace thermostat (WP 0028 00).

f. Add a 50/50 mixture of antifreeze
(Item 2 or 3, WP 0171 00) to radia-
tor. Leave radiator cap off.
g. Start engine and run until thermo-
stat opens and coolant level stabi-
lizes. Maintain level 1/2 in. (13
mm) from bottom of filter neck.
h. Inspect gasket of pressure cap and
replace if damaged. Install cap.
0010 00-73
TM 5-3800-205-23-1
Table 9. Water Distributor PMCS Mandatory Replacement Parts List - Initial 250 Hours.
ITEM PART
1 1R0719 2910-00-740-3593 Filter Element, Fluid Transmission 1

2 3J1907 5331-01-333-6444 O-ring 1
3 2S8439 5330-01-021-9880 Seal 1
Table 10. Water Distributor PMCS Mandatory Replacement Parts List - 250 Hours or Annual.
ITEM PART
1 1R0739 2940-00-029-0388 Filter Element, Fluid, Engine 1
Table 11. Water Distributor PMCS Mandatory Replacement Parts List - 500 Hours or Semiannual.
ITEM PART
1 1R0751 2910-01-424-7315 Filter Element, Fluid, Secondary Fuel Filter 2

2 117-4089 2910-01-443-6227 Filter Element, Fluid, Fuel/Water Separator 1
3 1328879 4330-01-509-0939 Filter Element, Fluid Hydraulic System 2
Table 12. Water Distributor PMCS Mandatory Replacement Parts List - 1000 Hours or Semiannual.
ITEM PART
1 1R0719 2910-00-740-3593 Filter Element, Fluid, Transmission (Annual) 1

2 3J1907 5331-01-333-6444 O-ring 1
3 5H7521 5331-00-555-3810 O-ring, Transmission Oil Section Screen Cover 1
4 2S8439 5330-01-021-9880 Seal 1
Table 13. Water Distributor PMCS Mandatory Replacement Parts List - 2000 Hours or Annual.
ITEM PART
1 1328876 4330-01-509-0939 Filter Element, Fluid, Hydraulic System 2

2 2S4663 5330-00-470-5727 Gasket, Valve Safety Relief 2
3 2767 5331-00-890-7586 O-ring, Front Axle Final Drive 2
4 5M2057 5331-00-855-8047 O-ring, Hydraulic Tank 1
5 3J1907 5331-01-333-6444 O-ring, Valve, Safety Relief 1
6 5P8132 5325-01-185-7726 Ring, Retaining 1
0010 00-74
TM 5-3800-205-23-1
Table 14. Water Distributor PMCS Mandatory Replacement Parts List - Biennial.
ITEM PART
1 195-7339 5330-01-508-2775 Gasket, Thermostat 1

2 126-5869 6685-01-474-2254 Thermostat 1
END OF WORK PACKAGE
0010 00-75
TM 5-3800-205-23-1
0010 00-76
TM 5-3800-205-23-1
CHAPTER 4
UNIT LEVEL TRACTOR MAINTENANCE
TM 5-3800-205-23-1

TM 5-3800-205-23-1
ROCKER ARM COVER REPLACEMENT 0011 00
THIS WORK PACKAGE COVERS
Removal, Installation
INITIAL SETUP
Maintenance Level Equipment Condition - Continued

Unit Scraper bowl or water tank lowered to ground (TM
5-3800-205-10-1 or TM 5-3800-205-10-2)
Tools and Special Tools
Parking brake applied (TM 5-3800-205-10-1 or TM
Tool kit, general mechanic’s (Item 33, WP 0172 5-3800-205-10-2)
00)
Wheels chocked (TM 5-3800-205-10-1 or TM 5-
Shop equpment, common no. 1 (Item 24, WP 3800-205-10-2)
0172 00)
Battery disconnect switch in OFF position (TM 5-
Equipment Condition 3800-205-10-1 or TM 5-3800-205-10-2)
Machine parked on hard, level surface (TM 5-3800- Engine access door opened (TM 5-3800-205-10-1
205-10-1 or TM 5-3800-205-10-2) or TM 5-3800-205-10-2)
CAUTION
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
REMOVAL
1. Remove 14 bolts (1), washers (2), rocker arm cover

(3) and gasket (4) from intake manifold (5). 1,2 3,4
2. Inspect gasket (4) for damage. Discard gasket if dam-
aged.
0011 00-1
TM 5-3800-205-23-1
ROCKER ARM COVER REPLACEMENT - CONTINUED 0011 00
INSTALLATION
1. If gasket (4) was removed, clean any remaining gasket material from rocker arm cover (3).
NOTE
Adhesive is NOT required. Gasket is designed to be installed dry.
2. If removed, position new gasket (4) on intake mani-

REAR FRONT
fold (5).
3. Install rocker arm cover (3) on cylinder head (5) with
14 washers (2) and bolts (1). Tighten bolts finger tight.
4. Tighten bolts (1) to 106 lb-in. (12 Nm) in sequence
illustrated.
390-1029
5. Close engine access door (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).
END OF WORK PACKAGE
0011 00-2
TM 5-3800-205-23-1
CRANKCASE BREATHER REPLACEMENT 0012 00
INITIAL SETUP

Unit
Scraper bowl or water tank lowered to ground (TM
Tools and Special Tools 5-3800-205-10-1 or TM 5-3800-205-10-2)
Tool kit, general mechanic’s (Item 33, WP 0172
00)
5-3800-205-10-2)
Shop equipment, common no. 1 (Item 24, WP
0172 00) Wheels chocked (TM 5-3800-205-10-1 or TM 5-
3800-205-10-2)
Materials/Parts
O-ring Battery disconnect switch in OFF position (TM 5-
3800-205-10-1 or TM 5-3800-205-10-2)
Equipment Condition
205-10-1) or TM 5-3800-205-10-2)
REMOVAL 2,3 4
1 5
1. Loosen clamp (4) and remove breather hose (5) from
crankcase breather (1).
2. Remove bolt (2), washer (3), crankcase breather (1),
and O-ring (8) from fuel filter base. Discard O-ring.
3. If breather hose (5) is damaged, loosen bolt (6) and
remove breather hose from clip (7).
390-345
8 (HIDDEN) 7 6
INSTALLATION
1. Install new O-ring (8) and crankcase breather (1) on fuel filter base with washer (3) and bolt (2). Tighten bolt to 62 lb-in.
(7 Nm).
2. Position breather hose (5) on crankcase breather (1) and tighten clamp (4).
3. If removed, install breather hose (5) in clip (7) with bolt (6). Tighten bolt to 62 lb-in. (7 Nm).
0012 00-1
TM 5-3800-205-23-1
END OF WORK PACKAGE
0012 00-2
TM 5-3800-205-23-1
ENGINE OIL FILTER REPLACEMENT 0013 00
INITIAL SETUP
Maintenance Level Materials/Parts

Unit Oil, lubricating (Item 25, 26 or 29, WP 0171 00)
Tools and Special Tools Filter element, fluid
Tool kit, general mechanic’s (Item 33, WP 0172 Equipment Condition
00)
Center guard plate removed (WP 0100 00)
0172 00) Engine oil drained (WP 0010 00)
NOTE
• Care must be taken to ensure that fluids are contained during performance of inspection, maintenance,
testing, adjusting and repair of the machine. Be prepared to collect fluid with suitable containers before
opening any compartment or disassembling any component containing fluids.
REMOVAL
Slowly remove engine oil filter (2) from oil filter base (1).
0013 00-1
TM 5-3800-205-23-1
ENGINE OIL FILTER REPLACEMENT - CONTINUED 0013 00
INSTALLATION
1. Apply a coat of clean engine oil to oil filter seal.
2. Install engine oil filter (2) on oil filter base (1) until seal contacts base, then tighten an additional 3/4 turn.
3. Fill engine oil (WP 0009 00 or WP 0010 00).
WARNING
4. Start engine and check for leaks (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).
5. Install center guard plate (WP 0100 00).
END OF WORK PACKAGE
0013 00-2
TM 5-3800-205-23-1
ENGINE OIL PAN REPLACEMENT 0014 00
INITIAL SETUP
Maintenance Level Materials/Parts - Continued

Unit Gasket
Tools and Special Tools Personnel Required

Tool kit, general mechanic’s (Item 33, WP 0172 Two
00) References
Shop equipment, common no. 1 (Item 24, WP WP 0009 00
0172 00)
Equipment Condition
Materials/Parts
Engine oil drained (WP 0010 00)
Oil, lubricating (Item 25, 26 or 29, WP 0171 00)
Front and center guard plates removed (WP 0100
Rag, wiping (Item 31, WP 0171 00) 00)
REMOVAL
1. Remove 36 bolts (1) and washers (2) from engine oil pan (3).
CAUTION
• Do NOT pry on engine oil pan. Damage to oil pan and/or engine mounting surfaces could result.
• Assistance is required when lowering oil pan due to size of oil pan. Failure to follow this caution may
result in damage to oil pan.
NOTE 1,2 3 4
(HIDDEN)
It may be necessary to tap lightly on oil
pan with a rubber mallet to break seal
between oil pan and engine block.
2. Lower engine oil pan (3) from engine.
3. Remove and discard oil pan gasket (4).
390-343
ENGINE NOT SHOWN
0014 00-1
TM 5-3800-205-23-1
ENGINE OIL PAN REPLACEMENT - CONTINUED 0014 00
INSTALLATION
1. Clean mating surfaces of engine oil pan (3) and cylin- 1,2 3 4
der block. (HIDDEN)
NOTE
Do NOT apply liquid gasket material on
oil pan or gasket surface of engine oil pan.
2. Position new gasket (4) on oil pan (3) and install
engine oil pan on cylinder block with 36 washers (2)
and bolts (1).
390-343
ENGINE NOT SHOWN

3. Tighten bolts (1) to 23 lb-ft (31 Nm) in the following sequence:
a. Tighten four bolts (5).
b. Starting with bolt (6), tighten remaining bolts in counterclockwise sequence.
5 5
6
390-344
5 5
4. Fill engine oil (WP 0009 00 and WP 0010 00).
WARNING
5. Start engine (TM 5-3800-205-10-1 or TM 5-3800-205-10-2), build up oil pressure, and stop engine. Check oil pan for
leaks.
6. Install front and center guard plates (WP 0100 00).
END OF WORK PACKAGE
0014 00-2
TM 5-3800-205-23-1
ENGINE OIL SAMPLING VALVE REPLACEMENT 0015 00
Removal
INITIAL SETUP
Maintenance Level Equipment Condition
Unit Machine parked on hard, level surface (TM 5-3800-

205-10-1 or TM 5-3800-205-10-2)
Tool kit, general mechanic’s (Item 33, WP 0172 5-3800-205-10-1 or TM 5-3800-205-10-2)
00)
Materials/Parts 5-3800-205-10-2)
Oil, lubricating (Item 25, 26 or 29, WP 0171 00) Wheel chocked (TM 5-3800-205-10-1 or TM 5-
3800-205-10-2)
Rag, wiping (Item 31, WP 0171 00)
O-ring 3800-205-10-1 or TM 5-3800-205-10-2)
REPLACEMENT
1. Remove oil sampling valve (2) and O-ring (3) from fitting (1). Discard O-ring.
2. Lightly coat new O-ring (3) with clean oil.
3. Install new O-ring (3) and oil sampling valve (2) to fitting (1).
.
1 2,3
390-991
0015 00-1
TM 5-3800-205-23-1
ENGINE OIL SAMPLING VALVE REPLACEMENT - CONTINUED 0015 00
REPLACEMENT - CONTINUED
WARNING
4. Start engine (TM 5-3800-205-10-1 or TM 5-3800-205-10-2) and build up oil pressure. Check for leaks.
END OF WORK PACKAGE
0015 00-2
TM 5-3800-205-23-1
FUEL LINES AND FITTINGS REPLACEMENT 0016 00
INITIAL SETUP

Unit
Machine parked on hard, level surface (TM 5-3800-
Tools and Special Tools 205-10-1 or TM 5-3800-205-10-2)
Tool kit, general mechanic’s (Item 33, WP 0172 Scraper bowl or water tank lowered to ground (TM
00)
5-3800-205-10-1 or TM 5-3800-205-10-2)
0172 00) Parking brake applied (TM 5-3800-205-10-1 or TM
5-3800-205-10-2)
Materials/Parts
Cap set, protective (Item 5, WP 0171 00) Wheels chocked (TM 5-3800-205-10-1 or TM 5-
3800-205-10-2)
Fuel (Item 13, 14 or 15, WP 0171 00)
Rag, wiping (Item 31, WP 0171 00) Battery disconnect switch in OFF position (TM 5-
Strap, tiedown (Item 38, WP 0171 00) 3800-205-10-1 or TM 5-3800-205-10-2)
Tag, marker (Item 39, WP 0171 00) Engine access door opened (TM 5-3800-205-10-1
O-ring (as required) or TM 5-3800-205-10-2)
WARNING
• DO NOT perform fuel system checks, inspections or maintenance while smoking or near fire, flames or
sparks. Fuel may ignite causing damage to machine and injury or death to personnel.
• Clean up all leaked or spilled fuel.
CAUTION
Cap all hoses to prevent fluid loss and contamination of fuel system.
NOTE
testing, adjusting and repair of the machine. Be prepared to collect fluid with a suitable container before
• Tag all hoses and fittings to aid in installation.
0016 00-1
TM 5-3800-205-23-1
FUEL LINES AND FITTINGS REPLACEMENT - CONTINUED 0016 00
REMOVAL
CAUTION
Use line wrenches to disconnect/connect fuel lines, to avoid damage to fittings.
NOTE
• Perform following steps to replace each of four tractor fuel hoses.
• Cut tiedown straps and remove screws and hose clamps as required to separate each hose from machine.
1. Disconnect hose (1) from fitting (2) at auxiliary fuel
tank connector (3). 1 2 (HIDDEN)
2. Disconnect other end of hose (1) from fitting (5) on

bracket (4). 4 5 1
3. Remove hose (1) from machine.
NOTE
Fittings include elbows, jamnuts, lock-
washers, adapters, O-rings, and tee. Dis-
card O-rings when removed.
4. Remove fittings (2 and 5) from machine.
0016 00-2
TM 5-3800-205-23-1
FUEL LINES AND FITTINGS REPLACEMENT - CONTINUED 0016 00
INSTALLATION
CAUTION
NOTE
Coat new O-rings with fuel prior to installation.
1. Install new O-rings and fittings (2 and 5) on machine.

2. Position hose (1) on machine.
3. Connect hose (1) to fitting (5) on bracket (4).
NOTE
Install hose clamps, screws, and new tiedown straps to secure each hose to machine.
4. Connect other end of hose (1) to fitting (2) at auxiliary fuel tank connector (3).
WARNING
5. Start engine (TM 5-3800-205-10-1 or TM 5-3800-205-10-2). Check for fuel leaks.
6. Close engine access dor (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).
END OF WORK PACKAGE
0016 00-3
TM 5-3800-205-23-1
0016 00-4
TM 5-3800-205-23-1
FUEL SHUTOFF SOLENOID REPLACEMENT 0017 00
INITIAL SETUP

00) 5-3800-205-10-1 or TM 5-3800-205-10-2)
Shop equipment, common no. 1 (Item 24, WP Parking brake applied (TM 5-3800-205-10-1 or TM
0172 00) 5-3800-205-10-2)
Wrench, spanner (Item 37, WP 0172 00)
Materials/Parts 3800-205-10-2)
Oil, lubricating (Item 24, 25, or 26, WP 0171 00)
Rag, wiping (Item 31, WP 0171 00) 3800-205-10-1 or TM 5-3800-205-10-2)
Tag, marker (Item 39, WP 0171 00) Engine access door opened (TM 5-3800-205-10-1
Seal or TM 5-3800-205-10-2)
WARNING
DO NOT perform fuel system checks, inspections or maintenance while smoking or near fire, flames or
sparks. Clean up all leaked or spilled fuel. Fuel may ignite causing damage to machine and injury or
death to personnel.
CAUTION
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
NOTE
• Tag all wires to aid in installation.
0017 00-1
TM 5-3800-205-23-1
FUEL SHUTOFF SOLENOID REPLACEMENT - CONTINUED 0017 00
REMOVAL
1. Remove three nuts (1), washer (2), two lockwashers
1,2,3 4 5 6
(3), and three wires (4) from fuel shutoff solenoid (5).
2. Using spanner wrench and ratchet wrench, remove
fuel shutoff solenoid (5) from fuel transfer pump/gov-
ernor (6).
3. Remove and discard seal from fuel shutoff solenoid
(5).
INSTALLATION
1. Apply a thin coat of engine oil to new seal and install seal on fuel shutoff solenoid (5).
2. Install fuel shutoff solenoid (5) on fuel transfer pump/governor (6). Tighten fuel shutoff solenoid to 22 lb-ft (30 Nm).
3. Install three wires (4) on fuel shutoff solenoid (5) with two lockwashers (3), washer (2), and three nuts (1).
END OF WORK PACKAGE
0017 00-2
TM 5-3800-205-23-1
AIR CLEANER ASSEMBLY MAINTENANCE 0018 00

Precleaner Replacement
Air Cleaner: Removal, Installation
INITIAL SETUP
Unit Machine parked on hard, level surface (TM 5-
3800-205-10-1 or TM 5-3800-205-10-2)
Tools and Special Tools Scraper bowl or water tank lowered to ground
Tool kit, general mechanic’s (Item 33, WP 0172 (TM 5-3800-205-10-1 or TM 5-3800-205-10-
00) 2)
Parking brake applied (TM 5-3800-205-10-1 or
Materials/Parts
TM 5-3800-205-10-2)
Filter element, intake, primary Wheels chocked (TM 5-3800-205-10-1 or TM 5-
Filter element, intake, secondary 3800-205-10-2)
Battery disconnect switch in OFF position (TM
Equipment Condition 5-3800-205-10-1 or TM 5-3800-205-10-2)
Batteries removed, if replacing air cleaner assem- Engine access door opened (TM 5-3800-205-10-1
bly (WP 0067 00) or TM 5-3800-205-10-2)
WARNING
• If NBC exposure is suspected, personnel wearing protective equipment should handle all air cleaner
media. Consult your NBC Officer or NBC NCO for appropriate handling or disposal procedures.
Failure to follow this warning may result in illness or death to personnel.
• NBC contaminated filters must be handled using adquate precautions (FM 21-10) and must be dis-
posed by trained personnel. Failure to follow this warning may result in illness or death to person-
nel.
PRECLEANER REPLACEMENT
1. Loosen clamp (2) and remove precleaner (1) from air 1
cleaner assembly.
2. Install precleaner (1) on air cleaner assembly and
2
tighten clamp (2).
390-979
0018 00-1
TM 5-3800-205-23-1
AIR CLEANER ASSEMBLY MAINTENANCE - CONTINUED 0018 00
AIR CLEANER REMOVAL

1. Remove precleaner (refer to Precleaner Replacement).
2. Open two clamps (3) and remove cover (4) from air cleaner assembly (5).
3. Remove air filter primary element (6) from air cleaner assembly (5).
3 6 5
390-050 390-051
5 4
4. Remove air filter secondary element (7) from air cleaner assembly (5).
5. Remove four screws (8) from plate (9). Remove plate from cover assembly.
7 5 8 9
390-052 390-053
0018 00-2
TM 5-3800-205-23-1
AIR CLEANER REMOVAL - CONTINUED

6. Remove bolt (10) and washer from bracket (12). Move bracket and windshield washer fluid reservoir (11) aside.
7. Remove eight nuts (13) and washers from studs (14).
10 11 13,14
12
8. Remove nut (15) and washer from strap assembly (16). Disconnect strap assembly from mounting plate assembly
(17). Lower strap assembly.
9. Lower air cleaner assembly (5) through mounting plate assembly (17). Move air cleaner assembly away from
machine.
10. If gasket (18) was damaged during removal of air cleaner assembly (5), replace damaged gasket with a new gasket.
AIR CLEANER INSTALLATION
1. Install air cleaner assembly (5). Install strap assembly (16) in mounting plate assembly (17). Install washer and nut
(15) on strap assembly.
15 16 17 3 5 18 5
390-056
390-057
0018 00-3
TM 5-3800-205-23-1
AIR CLEANER INSTALLATION - CONTINUED

2. Install eight washers and nuts (13) on studs (14).
3. Position bracket (12) and windshield washer fluid reservoir (11) to original position. Install washer and bolt (10) to
secure bracket to machine frame.
13,14 10 11
12
4. Install mounting plate (9). Install four screws (8) to secure mounting plate to machine frame.
5. Install a new air filter secondary element (7) in air cleaner assembly (5).
8 9 7 5
390-053 390-052
0018 00-4
TM 5-3800-205-23-1
AIR CLEANER INSTALLATION - CONTINUED

6. Install a new air filter primary element (6) in air cleaner assembly (5).
7. Install cover (4) to air cleaner assembly (5). Close two clamps (3).
8. Install precleaner (Refer to Precleaner Replacement).
9. Install batteries (WP 0067 00).
6 5 3
390-051 390-050
5 4
END OF WORK PACKAGE
0018 00-5
TM 5-3800-205-23-1
0018 00-6
TM 5-3800-205-23-1
AIR INTAKE HOSE REPLACEMENT 0019 00
Replacement
INITIAL SETUP

Unit
Tools and Special Tools 5-3800-205-10-2)
00)
3800-205-10-2)
Equipment Condition
Machine parked on hard, level ground (TM 5-3800-
3800-205-10-1 or TM 5-3800-205-10-2)
205-10-1 or TM 5-3800-205-10-2)
Scraper bowl or water tank lowered to ground (TM Engine access door opened (TM 5-3800-205-10-1
5-3800-205-10-1 or TM 5-3800-205-10-2) or TM 5-3800-205-10-2)
REPLACEMENT
1. Loosen four hose clamps (2) and remove air intake hose (3) from turbocharger (1) and air cleaner flange (4).
2. Position air intake hose (3) on air cleaner flange (4) and turbocharger (1) and tighten four hose clamps (2).
1 2 3
390-1271
2
END OF WORK PACKAGE
0019 00-1
TM 5-3800-205-23-1
0019 00-2
TM 5-3800-205-23-1
FUEL GOVERNOR HOSES AND LINES REPLACEMENT 0020 00
Fuel Hose: Removal, Installation
Fuel Tube: Removal, Installation
INITIAL SETUP

205-10-1 or TM 5-3800-205-10-2)
00) 5-3800-205-10-1 or TM 5-3800-205-10-2)
Materials/Parts Parking brake applied (TM 5-3800-205-10-1 or TM

5-3800-205-10-2)
Cap set, protective (Item 5, WP 0171 00)
Fuel (Item 13, 14 or 15, WP 0171 00)
3800-205-10-2)
Strap, tiedown (Item 38, WP 0171 00) 3800-205-10-1 or TM 5-3800-205-10-2)
Tag, marker (Item 39, WP 0171 00)
Engine access door opened (TM 5-3800-205-10-1
WARNING
• DO NOT perform fuel system checks, inspections or maintenance while smoking or near fire, flames or
sparks. Fuel may ignite, causing damage to machine and injury or death to personnel.
• Clean up all leaked or spilled fuel.
NOTE
0020 00-1
TM 5-3800-205-23-1
FUEL GOVERNOR HOSES AND LINES REPLACEMENT - CONTINUED 0020 00
FUEL HOSE REMOVAL
CAUTION
NOTE
• Perform following steps to remove each of four fuel hoses.
• Fittings include elbows, tees, adapters, and O-rings. Discard O-rings when removed.
1. Remove hose (2) and fitting (3) from governor (1). 1 2 3
NOTE
Cut tiedown straps and remove screws and hose clamps, as necessary, to separate each hose.
2. Remove other end of hose (2) and fitting (5) from sec- 4 5 2
ondary fuel filter (4).
0020 00-2
TM 5-3800-205-23-1
FUEL HOSE INSTALLATION
CAUTION
NOTE
• Perform following steps to install each of four fuel hoses.
• Coat new O-rings with fuel prior to installation.
1. Install new O-rings.
2. Install fitting (5) and hose (2) on secondary fuel filter (4).
3. Install fitting (3) and other end of hose (2) on governor (1).
4. Install hose clamp, screws, and new tiedown straps, as needed, to secure hose (2).
WARNING
5. Start engine (TM 5-3800-205-10-1 or TM 5-3800-205-10-2) and check for fuel leaks.
FUEL TUBE REMOVAL
NOTE
• Perform following steps to remove fuel ratio control tube or two fuel tubes.
• Fittings include elbows, adapters and O-rings. Discard O-rings when removed.
1. Remove fuel tube (7) and fitting (6) from governor 6 (HIDDEN) 1
(1).
9
FUEL RATIO 7
8
CONTROL TUBE
0020 00-3
TM 5-3800-205-23-1
FUEL TUBE REMOVAL - CONTINUED
2. Remove screw and hose clamp, as necessary, to sepa- 6 (HIDDEN) 1

rate each fuel tube.
3. Remove other end of fuel tube (7) and fitting (9) from
engine inlet manifold (8).
4. Remove fuel tube (7).
9
FUEL RATIO 7
8
CONTROL TUBE
FUEL TUBE INSTALLATION
CAUTION
NOTE
• Perform following steps to install fuel ratio control tube or two fuel tubes.
• Coat new O-rings with fuel prior to installation.
1. Install new O-rings.
2. Position fuel tube (7) on engine.
3. Install fitting (9) and fuel tube (7) on inlet manifold (8).
4. Install hose clamp and screw, as necessary, to secure each fuel tube.
5. Install fitting (6) and other end of fuel tube (7) on governor (1).
WARNING
NOTE
It may be necessary to prime fuel system.
0020 00-4
TM 5-3800-205-23-1
FUEL TUBE INSTALLATION - CONTINUED
6. Start engine (TM 5-3800-205-10-1 or TM 5-3800-205-10-2) and check for fuel leaks.
END OF WORK PACKAGE
0020 00-5
TM 5-3800-205-23-1
0020 00-6
TM 5-3800-205-23-1
SECONDARY FUEL FILTERS AND BASE REPLACEMENT 0021 00
INITIAL SETUP

205-10-1 or TM 5-3800-205-10-2)
00)
5-3800-205-10-2)
0172 00)
Fuel (Item 13, 14 or 15, WP 0171 00) 3800-205-10-1 or TM 5-3800-205-10-2)
Rag, wiping (Item 31, WP 0171 00) Fuel line quick disconnect disconnected at draft
arm (TM 5-3800-205-10-1 or TM 5-3800-205-
10-2)
Filter element, fluid (2)
WARNING
sparks. Clean up all leaked or spilled fuel. Fuel may ignite, causing damage to machine and injury or
death to personnel.
NOTE
• Tag all hoses and wires to aid in installation. Cap all hoses and fittings to prevent fluid loss and contam-
ination of fuel system.
0021 00-1
TM 5-3800-205-23-1
SECONDARY FUEL FILTERS AND BASE REPLACEMENT - CONTINUED 0021 00
REMOVAL
1. Place a suitable container under ends of two drain 1
hoses (2).
2. Open two drain valves (4) and allow excess fuel to 5
drain from fuel filter base (5). Close drain valves.
3. Remove two fuel filter elements (1) from fuel filter
base (5). Discard filter elements.
4. Loosen two hose clamps (3) and remove two drain
hoses (2) from elbows at fuel filter base (5).
5. Remove fuel pressure sensor (7) connector and wiring 6 7

harness (8) connector from clip (9) and disconnect.
6. Remove fuel pressure sensor (7) from adapter at side
of fuel filter base (5).
7. Disconnect fuel hose (6) from elbow.
9 8
0021 00-2
TM 5-3800-205-23-1
REMOVAL - CONTINUED
8. At opposite side of fuel filter base (5), disconnect two 5 10 11
fuel hoses (11) from two elbows.
9. Remove four screws (12), washers (13), and fuel filter
base (5) from bracket (10).
10. Remove fittings from fuel filter base (5). Remove O-
rings from fittings and discard.
12,13
11. Remove four screws (15), washers (16), clip (9),

clamp (17), bracket (10), and lifting eye (14) from rear 9 14 15,16
of engine.
10 17
0021 00-3
TM 5-3800-205-23-1
INSTALLATION
1. Install lifting eye (14), bracket (10), clamp (17), and
clip (9) on rear of engine with four washers (16) and 9 14 15,16
screws (15).
10 17
2. Coat new fitting O-rings with fuel and install O-rings 5 10 11

and fittings on fuel filter base (5).
3. Install fuel filter base (5) on bracket (10) with four
washers (13) and screws (12).
4. At side of fuel filter base (5), connect two fuel hoses
(11) to two elbows.
12,13
0021 00-4
TM 5-3800-205-23-1
INSTALLATION - CONTINUED
5. At opposite side of fuel filter base (5), connect fuel 6 7
hose (6) to elbow.
6. Install fuel pressure sensor (7) to adapter at side of
fuel filter base (5).
7. Connect pressure sensor (7) connector to wiring har-
ness (8) connector and install in clip (9).
9 8
8. Position two drain hoses (2) on two elbows at drain 1

valves (4) of fuel filter base (5) and tighten two hose
clamps (3). 5
9. Apply a thin coat of fuel to rubber seal of two new fuel
filter elements (1).
10. Install two fuel filter elements (1) to fuel filter base (5)
until rubber seal contacts surface of fuel filter base.
Tighten each filter element an additional 3/4 turn.
0021 00-5
TM 5-3800-205-23-1
11. Connect fuel line quick disconnect at draft arm (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).
12. Place battery disconnect switch in ON position (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).
13. Prime fuel system to fill fuel filters (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).
WARNING
14. Start engine (TM 5-3800-205-10-1 and TM 5-3800-205-10-2) and check for fuel leaks.
15. Close engine access door (TM 5-3800-205-10 and TM 5-3800-205-10-2).
END OF WORK PACKAGE
0021 00-6
TM 5-3800-205-23-1
ETHER COLD START AID SYSTEM MAINTENANCE 0022 00
Ether Cylinder Replacement

Clamp and Solenoid Valve: Removal, Installation
Ether Atomizer Replacement
INITIAL SETUP
Unit
Scraper bowl or water tank lowered to ground
Tools and Special Tools (TM 5-3800-205-10-1 or TM 5-3800-205-10-
Tool kit, general mechanic’s (Item 33, WP 0172 2)
00)
Materials/Parts
5-3800-205-10-2)
Gasket
O-ring Wheels chocked (TM 5-3800-205-10-1 or TM 5-
3800-205-10-2)
Equipment Condition
Machine parked on hard, level surface (TM 5-3800- Battery disconnect switch in OFF position (TM
205-10-1 or TM 5-3800-205-10-2) 5-3800-205-10-1 or TM 5-3800-205-10-2)
WARNING
Ether fuel is extremely flammable and toxic. DO NOT smoke and make sure you are in a well-ventilated
area away from heat, open flames or sparks. Wear eye protection. Avoid contact with skin and eyes and
avoid breathing ether fumes. If fluid enters or fumes irritate the eyes, wash immediately with large quantities
of clean water for 15 minutes. Seek medical attention immediately if ether is inhaled or causes eye irritation.
Failure to follow this warning may cause death or serious injury to personnel.
0022 00-1
TM 5-3800-205-23-1
ETHER COLD START AID SYSTEM MAINTENANCE - CONTINUED 0022 00
ETHER CYLINDER REPLACEMENT

1. Loosen thumbscrew (3) of retaining clamp (2) and 1
rotate ether cylinder (1) counterclockwise to remove
from solenoid valve (4).
2. Remove gasket (5) from solenoid valve (4). Discard 2
gasket.
3. Position new gasket (5) in solenoid valve (4).
4. Install ether cylinder (1) on solenoid valve (4) by
rotating clockwise until hand tight. 3
5. Tighten thumbscrew (3) of retaining clamp (2).
4,5
CLAMP AND SOLENOID VALVE REMOVAL

1. Remove ether cylinder (refer to Ether Cylinder
2
Replacement). 6,7,8
2. Install protective cap (10) on solenoid valve (4).
3. Remove two nuts (6), screws (7), four washers (8), 9
and retaining clamp (2) from left fender bracket (9).
4. Remove solenoid valve connector (14) and wiring har-
ness (19) from clip (15). Disconnect connectors. 10
5. Remove fitting (12) and tube (13) from elbow (11).
6. Remove elbow (11) from solenoid valve (4). 19
4
7. Remove two nuts (16), screws (17), four washers (18), 16,17,18 11
clip (15), and solenoid valve (4) from left fender
15 12
bracket (9).
14
13
0022 00-2
TM 5-3800-205-23-1
ETHER COLD START AID SYSTEM MAINTENANCE - CONTINUED 0022 00
CLAMP AND SOLENOID VALVE INSTALLATION
1. Install solenoid valve (4) and clip (15) on left fender bracket (9) with four washers (18), two screws (17), and nuts (16).
2. Install elbow (11) on solenoid valve (4).
3. Install tube (13) and fitting (12) on elbow (11).
4. Connect solenoid valve connector (14) to wiring harness connector (19) and install in clip (15).
5. Install retaining clamp (2) on left fender bracket (9) with four washers (18), two screws (17), and nuts (16).
6. Remove protective cap (10) from solenoid valve (4).
7. Install ether cylinder (refer to Ether Cylinder Replacement).
ETHER ATOMIZER REPLACEMENT
1. At top of engine, remove fitting (20) and tube (13) 13
from atomizer (21).
20
2. Remove atomizer (21) from adapter (22).
21
3. Remove adapter (22) and O-ring (23) from engine.
Discard O-ring. 22,23
4. Install new O-ring (23) and adapter (22) on engine.
NOTE
Position atomizer so that direction of spray
is parallel to air inlet heater.
5. Install atomizer (21) on adapter (22).
6. Install tube (13) and fitting (20) on atomizer (21).
END OF WORK PACKAGE
0022 00-3
TM 5-3800-205-23-1
0022 00-4
TM 5-3800-205-23-1
ACCELERATOR PEDAL REPLACEMENT 0023 00
INITIAL SETUP

5-3800-205-10-1 or TM 5-3800-205-10-2)
00)
Equipment Condition 3800-205-10-2)
Machine parked on hard, level surface (TM 5-380- Battery disconnect switch in OFF position (TM 5-
205-10-1 or TM 5-3800-205-10-2) 3800-205-10-1 or TM 5-3800-205-10-2)
REMOVAL
1. Remove bolt (6) from clamp (5).

2. Remove two bolts (2) from bracket (3).
3. Slide pedal assembly (1) and bracket (3) off of accelerator shaft (7).
4. Remove woodruff key (4) from accelerator shaft (7). Discard woodruff key if damaged.
6 5 4 3 2
0023 00-1
TM 5-3800-205-23-1
ACCELERATOR PEDAL REPLACEMENT - CONTINUED 0023 00
INSTALLATION
1. Slide pedal assembly (1) on accelerator shaft (7).
2. Install bracket (3) with two bolts (2). Tighten bolts.
3. Install bolt (6) on clamp (5) and tighten.
4. Install woodruff key (4) on accelerator shaft (7).
6 5 4 3 2
END OF WORK PACKAGE
0023 00-2
TM 5-3800-205-23-1
THROTTLE CONTROL CABLE REPLACEMENT 0024 00
INITIAL SETUP

Unit Center guard plate removed (WP 0100 00)
Tools and Special Tools Engine access door opened (TM 5-3800-205-10-1
or TM 5-3800-205-10-2)
00)
REMOVAL
1. Remove nut (1), washer (2), and ball joint (3) from lever (4).
1,2 (HIDDEN)
0024 00-1
TM 5-3800-205-23-1
THROTTLE CONTROL CABLE REPLACEMENT - CONTINUED 0024 00
REMOVAL - CONTINUED
NOTE
• Count threads on control cable adjuster from jamnut and mark location to aid in installation.
• Use two wrenches to loosen jamnuts.
2. Hold jamnut (5) while loosening jamnut (6).

3. Remove control cable (7) from bracket (8). 5 6 7
NOTE
Disconnect control cable and linkage from linkage underneath tractor.
4. Disconnect accelerator spring (9).

5. Hold nut (13) and remove nut (11) and washer (12). 10 11 12 13
6. Remove control cable (7) from accelerator pedal lever
(10).
0024 00-2
TM 5-3800-205-23-1
REMOVAL - CONTINUED
NOTE
• Count threads on control cable adjuster from jamnut and mark location for installation.
• Use two wrenches to loosen jamnuts.
7. Hold jamnut (17) and remove jamnut (14) and star-
washer (15) from control cable (7). 14 7
8. Slide control cable (7) through bracket (16) and
remove from machine.
15,17 16 15
INSTALLATION
1. Slide control cable (7) through bracket (16), with jamnut (17) and starwasher (15) on one side of bracket.
2. Install starwasher (15) and jamnut (14).
3. Install control cable (7) on accelerator pedal lever (10).
4. Install washer (12) and nut (11).
5. Connect accelerator spring (9).
6. Install control cable (7) on bracket (8) with jamnut (5) and starwasher on one side of bracket.
7. Install starwasher (15) and jamnut (6).
8. Position ball joint (3) in lever (4).
9. Install nut (1) and washer (2).
5,15 15 6 1,2
0024 00-3
TM 5-3800-205-23-1
10. Tighten jamnut (5) while holding jamnut (6).
5 6
11. Adjust jamnuts (5, 6, and 14) for full throttle opera-
tions with accelerator pedal. 14

END OF WORK PACKAGE
0024 00-4
TM 5-3800-205-23-1
EXHAUST GUARD, EXHAUST PIPE, AND MUFFLER REPLACEMENT 0025 00

INITIAL SETUP
Tool kit, general mechanic’s (Item 33, WP 0172 Parking brake applied (TM 5-3800-205-10-1 or TM
00) 5-3800-205-10-2)
Sling, nylon (Item 27, WP 0172 00) Wheels chocked (TM 5-3800-205-10-1 or TM 5-
Personnel Required 3800-205-10-2)
Two Battery disconnect switch in OFF position (TM 5-
Machine parked on hard, level surface (TM 5-380- Engine access door removed, if replacing muffler
205-10-1 or TM 5-3800-205-10-2) (WP 0097 00)
WARNING
Do NOT remove guard, exhaust or muffler until they have cooled to the touch. Wear gloves and protective
clothing as required to protect against burns. Failure to follow this warning may cause personnel injury.
REMOVAL
1. Remove two screws (1) and washers (2) from top and
bottom of exhaust guard (8). 3,4
2. Inspect two clamps (5) for cracks or damage. If
clamps are cracked or damaged, remove two nuts (6), 1,2 5,6,7
washers (7), screws (3), washers (4), and clamps.
1,2
0025 00-1
TM 5-3800-205-23-1
EXHAUST GUARD, EXHAUST PIPE, AND MUFFLER REPLACEMENT - CONTINUED 0025 00
REMOVAL - CONTINUED
3. Loosen clamp (9) and remove exhaust pipe (10) from
muffler (11). 9 10
390-887
11
4. Loosen exhaust clamp (12) and disconnect elbow (13) from muffler (11).
5. Remove six bolts (14) and plate (15) from machine.
11 12 13 14 15
390-1188
6. Remove four nuts (16) and two clamps (17) from bracket assembly (18).
WARNING
Use extreme caution when handling heavy parts. Provide adequate support and use assistance during proce-
dure. Failure to follow this warning may result in injury to personnel.
NOTE
Muffler weighs 42 lb (19 kg).
0025 00-2
TM 5-3800-205-23-1
REMOVAL - CONTINUED
7. Wrap a nylon sling around muffler (11) and attach to a 16 17 11
suitable lifting device.
8. Remove muffler (11) from bracket assembly (18).
390-061
18
INSTALLATION
WARNING
NOTE
Muffler weighs 42 lb (19 kg).
1. Wrap a nylon sling around muffler (11). Use a suitable lifting device to position muffler on bracket assembly (18).
2. Install two clamps (17) on bracket assembly (18) with four nuts (16).
3. Install plate (15) on machine with six bolts (14).
4. Position elbow (13) on muffler (11) and tighten exhaust clamp (12).
0025 00-3
TM 5-3800-205-23-1
NOTE
Position exhaust pipe on muffler with tip of exhaust pipe pointing away from cab.
5. Position exhaust pipe (10) on muffler (11) and tighten

clamp (9). 9 10
390-887
11
6. If removed, install two clamps (5) with two washers

(4), screws (3), washers (7), and nuts (6). 3,4
7. Install guard (8) on clamps (5) with two screws (1)
and washers (2).
1,2 5,6,7
1,2
8. Install engine access door, if removed (WP 0100 00).
END OF WORK PACKAGE
0025 00-4
TM 5-3800-205-23-1
HYDRAULIC OIL COOLER REPLACEMENT 0026 00
INITIAL SETUP
Maintenance Level References

Unit WP 0009 00
Tools and Special Tools Equipment Condition

Tool kit, general mechanic’s (Item 33, WP 0172 Machine parked on hard, level surface (TM 5-380-
00) 205-10-1 or TM 5-3800-205-10-2)
Shop equipment, common no. 1 (Item 24, WP Scraper bowl or water tank lowered to ground (TM
0172 00) 5-3800-205-10-1 or TM 5-3800-205-10-2)

5-3800-205-10-2)
Oil, lubricating (Item 24 or 29, WP 0171 00) 3800-205-10-2)
Tag, marker (Item 39, WP 0171 00) 3800-205-10-1 or TM 5-3800-205-10-2)
O-ring (2) Hydraulic system drained (WP 0010 00)
WARNING
• DO NOT disconnect or remove any hydraulic system line or fitting unless engine is shut down and
hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escap-
ing hydraulic fluid under pressure can penetrate the skin, causing serious injury.
• At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any
hydraulic lines. Failure to do so could result in injury.
• Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may
0026 00-1
TM 5-3800-205-23-1
HYDRAULIC OIL COOLER REPLACEMENT - CONTINUED 0026 00
NOTE
• Tag all hoses to aid in installation.
• Cap hoses to prevent fluid loss and contamination of the hydraulic system.
REMOVAL
1. Relieve hydraulic system pressure by moving control
levers through all positions (TM 5-3800-205-10-1 or 1,2,3 4
TM 5-3800-205-10-2).
2. Remove eight plugs (1) from front of engine grille (4).
3. With assistance, remove eight bolts (2), washers (3),
and engine grille (4) from front of machine.
4. Disconnect two hydraulic hoses (6) from two elbows 5 6

(5) of hydraulic oil cooler (7).
0026 00-2
TM 5-3800-205-23-1
REMOVAL - CONTINUED
NOTE
Hose clamp with hose is also removed as hydraulic oil cooler is removed.
5. Remove four nuts (8), bolts (9), eight washers (10)

8,9,10 7
and hydraulic oil cooler (7) from two oil cooler brack-
ets (11).
11
NOTE
Note position of two elbows for installation.
6. Remove two elbows (5) from hydraulic oil cooler (7).

Remove O-ring (12) from each elbow. Discard O- 7 5,12
rings.
0026 00-3
TM 5-3800-205-23-1
REMOVAL - CONTINUED
7. Remove four nuts (13), bolts (14), eight washers (15),
and two oil cooler brackets (11) from four transmis- 11 13,14,15 16
sion oil cooler brackets (16).
INSTALLATION
1. Install two oil cooler brackets (11) to four transmission oil cooler brackets (16) with eight washers (15), four bolts (14),
and nuts (13).
NOTE
Coat new O-rings with oil prior to installation.
2. Install new O-ring (12) to each of two elbows (5) and

install elbows to hydraulic oil cooler (7). 7 5,12
0026 00-4
TM 5-3800-205-23-1
NOTE
Hose clamp with hose is also installed as hydraulic oil cooler is installed.
3. Install hydraulic oil cooler (7) to two oil cooler brack-

8,9,10 7
ets (11) with eight washers (10), four bolts (9), and
nuts (8).
11
0026 00-5
TM 5-3800-205-23-1
4. Connect two hydraulic hoses (6) to two elbows (5) of 5 6
hydraulic oil cooler (7).
5. Fill hydraulic system (WP 0009 00 and WP 0010 00).
0026 00-6
TM 5-3800-205-23-1
WARNING
Carbon monoxide is a colorless, odorless, deadly poison which, when breathed, deprives the body of oxygen
and causes suffocation. Exposure to air containing carbon monoxide produces symptoms of headache, dizzi-
ness, loss of muscular control, apparent drowsiness, and coma. Permanent brain damage or death can result
from severe exposure.
6. Start engine (TM 5-3800-205-10-1 or TM 5-3800- 1,2,3 4
205-10-2).
7. Operate hydraulic system (TM 5-3800-205-10-1 or
TM 5-3800-205-10-2) and check for leaks.
8. Install engine grille (4) to front of machine with eight
washers (3) and bolts (2).
9. Install eight plugs (1) to front of engine grille (4).
END OF WORK PACKAGE
0026 00-7
TM 5-3800-205-23-1
0026 00-8
TM 5-3800-205-23-1
RADIATOR HOSES, TUBES, AND CLAMPS REPLACEMENT 0027 00
Upper Radiator Hose: Removal, Installation

Lower Radiator Hose: Removal, Installation
Overflow Hose: Removal, Installation
INITIAL SETUP

WP 0009 00
Unit
Equipment Condition
Front guard plate removed, if removing lower radi-
Tool kit, general mechanic’s (Item 33, WP 0172 ator hose and overflow hose (WP 0100 00)
00) Coolant drained (WP 0010 00)
WARNING
• DO NOT service cooling system unless engine has been allowed to cool down. This is a pressurized
cooling system and escaping steam or hot coolant will cause serious burns.
• DO NOT remove cooling system radiator cap when engine is hot. Allow engine to cool down. Failure to
follow this warning may cause serious burns.
• Wear effective eye, glove, and skin protection when handling coolants. Failure to do so may cause
injury.
NOTE
• Care must be taken to ensure that fluids are contained during performance of inspections, maintenance,
testing, adjusting and repair of the machine. Be prepared to collect fluid with suitable container before
• Dispose of all fluids in accordance with local mandates and regulations.
0027 00-1
TM 5-3800-205-23-1
RADIATOR HOSES, TUBES, AND CLAMPS REPLACEMENT - CONTINUED 0027 00
UPPER RADIATOR HOSE REMOVAL

1. Remove four hose clamps (4) from upper radiator
hoses (1 and 3).
2. Separate upper radiator hoses (1 and 3) from tube (2). 1 2
UPPER RADIATOR HOSE INSTALLATION

Position upper radiator hoses (1 and 3) on tube (2) and install four hose clamps (4).
LOWER RADIATOR HOSE REMOVAL
1. Loosen two hose clamps (9) and remove hose (8) from
water pump inlet and from connector tube (7).
2. Loosen two hose clamps (5) and remove hose (6) from
outlet of radiator and connector tube (7).
7 6
8
0027 00-2
TM 5-3800-205-23-1
RADIATOR HOSES, TUBES, AND CLAMPS REPLACEMENT - CONTINUED 0027 00
LOWER RADIATOR HOSE INSTALLATION

1. Position hose (8) on water pump inlet and connector tube (7) and install two clamps (9).
2. Position hose (6) on radiator outlet and connector tube (7) and install two clamps (5).
OVERFLOW HOSE REMOVAL
1. Loosen two hose clamps (10).
2. Remove three screws (11), washers (12), and clamps
(13).
3. Remove hose (14) from radiator (12) and connector
10
tube (7).
11,12,13
14
12
OVERFLOW HOSE INSTALLATION

1. Position hose (14) on connector tube (7) and radiator (12) and install two hose clamps (10).
2. Secure hose (14) with three clamps (13), washers (12), and screws (11).
3. Refill coolant and check for leaks (WP 0009 00 and WP 0010 00).
4. If removed, install front guard plate (WP 0100 00)
END OF WORK PACKAGE
0027 00-3
TM 5-3800-205-23-1
0027 00-4
TM 5-3800-205-23-1
THERMOSTAT REPLACEMENT 0028 00
INITIAL SETUP

Unit
5-3800-205-10-1 or TM 5-3800-205-10-2)
Tools and Special Tools Parking brake applied (TM 5-3800-205-10-1 or TM
5-3800-205-10-2)
00) Wheels chocked (TM 5-3800-205-10-1 or TM 5-
3800-205-10-2)
Materials/Parts Battery disconnect switch in OFF position (TM 5-
3800-205-10-1 or TM 5-3800-205-10-2)
Gasket
Coolant drained (WP 0010 00)
References
WP 0009 00
Equipment Condition

205-10-1 or TM 5-3800-205-10-2)
WARNING
• DO NOT service cooling system unless engine has been allowed to cool down. This is a pressurized
cooling system and escaping steam or hot coolant will cause serious burns.
• DO NOT remove cooling system radiator cap when engine is hot. Allow engine to cool down. Failure to
follow this warning may cause serious burns.
• Wear effective eye, glove, and skin protection when handling coolants. Failure to do so may cause
injury.
NOTE
0028 00-1
TM 5-3800-205-23-1
THERMOSTAT REPLACEMENT - CONTINUED 0028 00
REMOVAL
1. Remove two bolts (2), washers, and clip (3) from ther- 1 2 3
mostat housing (4). Move tube (1) to the side.
390-929
4
2. Remove thermostat (5) from thermostat housing (4) 5
390-930
4
0028 00-2
TM 5-3800-205-23-1
REMOVAL - CONTINUED
3. Remove and discard gasket (6) from thermostat hous- 6
ing (4).
390-931
4
INSTALLATION
NOTE
Ensure that thermostat gasket mounting surface is clean.
1. Install new gasket (6) on thermostat housing (4).

2. Install thermostat (5) on thermostat housing (4). 5
390-930
4
0028 00-3
TM 5-3800-205-23-1
3. Install tube (1) on thermostat housing (4) with clip (3), 1 2 3
two washers, and bolts (2).
390-929
4. Fill cooling system (WP 0009 00 and WP 0010 00).
WARNING
5. Start engine (TM 5-3800-205-10-1 or TM 5-3800-205-10-2) and check for leaks.
6. Close engine access cover (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).
END OF WORK PACKAGE
0028 00-4
TM 5-3800-205-23-1
WATER PUMP REPLACEMENT 0029 00
INITIAL SETUP

Unit TM 5-3800-205-10-1
Tools and Special Tools TM 5-3800-205-10-2
Tool kit, general mechanic’s (Item 33, WP 0172 WP 0009 00
00)
Equipment Condition
0172 00) Alternator removed (WP 0034 00)
Materials/Parts Fan removed (WP 0031 00)

O-ring (2) Coolant drained (WP 0010 00)
NOTE
REMOVAL
1. Remove four bolts (1) and bracket (2) from water 1

pump.
0029 00-1
TM 5-3800-205-23-1
WATER PUMP REPLACEMENT - CONTINUED 0029 00
REMOVAL - CONTINUED 4 5
3
2. Loosen hose clamps (3 and 4) and disconnect hoses (5
and 7) from aftercooler and water pump. Loosen hose
clamp (6).
7 6
3. Loosen retaining nut (8) and disconnect hose (9) from 8 9

O-ring port tee.
4. Loosen hose clamp (11) and disconnect hose (10)
from water pump.
11
10
5. Remove four screws (12), water pump, and two O-

rings from engine. Discard O-rings.
12
0029 00-2
TM 5-3800-205-23-1
WATER PUMP REPLACEMENT - CONTINUED 0029 00
INSTALLATION
1. Install two new O-rings and water pump on engine with four screws (12).
2. Connect hose (10) to water pump and tighten hose clamp (11).
3. Connect hose (9) to O-ring port tee and tighten retaining nut (8).
4. Connect hoses (5 and 7) to aftercooler and water pump and tighten hose clamps (3 and 4). Tighten hose clamp (6).
5. Install bracket (2) on water pump with four bolts (1). 1
6. Install alternator (WP 0034 00).

7. Install fan drive (WP 0031 00).
8. Refill cooling system (WP 0009 00 and WP 0010 00).
WARNING
9. Start engine (TM 5-3800-205-10-1 or TM 5-3800-205-10-2). Check for coolant leaks.
END OF WORK PACKAGE
0029 00-3
TM 5-3800-205-23-1
0029 00-4
TM 5-3800-205-23-1
BELT TIGHTENER REPLACEMENT 0030 00
INITIAL SETUP

Unit WP 0032 00
Equipment Condition
00) Alternator removed (WP 0034 00)
REMOVAL
1. Remove two bolts (1) and water pump belt tightener 1 2

(3) from timing gear housing.
2. Remove V-belt (2) from water pump belt tightener (3)
pulley.
INSTALLATION
1. Install water pump belt tightener (3) on timing gear housing with two bolts (1).
2. Install V-belt (2) on water pump belt tightener pulley.
3. Adjust V-belt (2) tension (WP 0032 00).
4. Install alternator (WP 0034 00).
END OF WORK PACKAGE
0030 00-1
TM 5-3800-205-23-1
0030 00-2
TM 5-3800-205-23-1
FAN AND FAN DRIVE REPLACEMENT 0031 00
INITIAL SETUP

Unit WP 0032 00
Tools and Special Tools Personnel Required
Tool kit, general mechanic’s (Item 33, WP 0172 Two
00)
Equipment Condition
0172 00) Engine access door removed (WP 0099 00)
Bracket, link (Item 6, WP 0172 00) Front guard plate removed (WP 0100 00)
Sling, nylon (Item 27, WP 0172 00) Hydraulic oil cooler removed (WP 0026 00)
Block, wood Transmission oil cooler removed (WP 0074 00)
REMOVAL
1. Loosen hose clamp (4) and remove hose (5) from radi-
ator assembly. 1 2 3 4 6
5
2. Remove two bolts (3) from fan guards (1 and 6).
3. Remove ten bolts (2) from fan guards (1 and 6) and
hose (5) clips.
4. Remove fan guards (1 and 6) from radiator assembly.
Reposition hose (5) out of the way.
390-070
0031 00-1
TM 5-3800-205-23-1
FAN AND FAN DRIVE REPLACEMENT - CONTINUED 0031 00
REMOVAL - CONTINUED
5. Remove four bolts (8) from radiator mounting brack- 7 8
ets (7).
390-085
6. Lean radiator assembly (10) forward for clearance and 9 10 11 12

use a wood block (9) to brace radiator assembly.
7. Remove six bolts (12) from fan assembly (11). Place
fan assembly in radiator assembly (10) shroud.
390-107
8. Loosen bolts (14 and 15) and tilt alternator (17) 13 14 15 16

toward engine. Remove two V-belts (16) from drive
pulley (13).
390-108
17
0031 00-2
TM 5-3800-205-23-1
REMOVAL - CONTINUED
9. Remove two bolts (20) and governor assembly (19) 18 19 20
from fan drive (18).
390-109
WARNING
dure. Ensure that any lifting device used is in good condition and of suitable lift capacity. Keep clear of
heavy parts supported only by lifting device. Failure to follow this warning may result in death or injury to
personnel.
10. Attach link bracket, nylon sling, and suitable lifting 18
device to fan drive (18). Remove four bolts (21) and
fan drive from engine as a unit. Bolts are removed
from fan drive during repair procedure.
390-110
21
0031 00-3
TM 5-3800-205-23-1
REMOVAL - CONTINUED
11. Remove engine lifting bracket (22) from four bolts 22 18
(21) and fan drive (18).
12. Remove fan assembly from radiator assembly shroud.
21 390-111
INSTALLATION
1. Position fan assembly in radiator assembly shroud.
WARNING
personnel.
2. Attach link bracket, nylon sling, and suitable lifting device to fan drive (18). Install engine lifting bracket (22) on
four bolts (21) and fan drive.
3. Install four bolts (21), engine lifting bracket (22), and 18
fan drive (18) on engine as a unit.
390-110
21
0031 00-4
TM 5-3800-205-23-1
4. Install governor assembly (19) on fan drive (18) with 18 19 20
two bolts (20).
390-109
NOTE
Do NOT adjust V-belts if equipped with a spring-loaded tensioner.
5. Tilt alternator (17) toward engine and install two V- 13 14 15 16

belts (16) on drive pulley (13).
6. Adjust V-belts (WP 0032 00).
7. Tighten bolts (14 and 15).
390-108
17
0031 00-5
TM 5-3800-205-23-1
8. Install fan assembly (11) on fan drive (18) with six 9 10 11 12
bolts (12).
9. Remove wood block (9) and place radiator assembly
(10) in upright position.
390-107
10. Install four bolts (8) on radiator mounting brackets (7). 7 8
390-085
0031 00-6
TM 5-3800-205-23-1
11. Position fan guards (1 and 6) to radiator assembly and

install ten bolts (2) on fan guards and hose (5) clips. 1 2 3 4 6
5
12. Install two bolts (3) on fan guards (1 and 6).
13. Position hose (5) on radiator assembly and tighten
hose clamp (4).
390-070
14. Install transmission oil cooler (WP 0074 00).

15. Install hydraulic oil cooler (WP 0026 00).
16. Install engine access door (WP 0099 00).
17. Install front guard plate (WP 0100 00).
END OF WORK PACKAGE
0031 00-7
TM 5-3800-205-23-1
0031 00-8
TM 5-3800-205-23-1
FAN, ALTERNATOR, AND WATER PUMP DRIVE BELTS REPLACEMENT 0032 00
INITIAL SETUP

Unit Fan removed (WP 0031 00)

00)
0172 00)
REMOVAL
NOTE
Radiator has been removed for clarity.
1. Loosen bolts (2 and 4) and tilt alternator (5) toward engine. Remove two V-belts (3) from drive pulley (1).
1 2 3
390-108
5
4
0032 00-1
TM 5-3800-205-23-1
FAN, ALTERNATOR, AND WATER PUMP DRIVE BELTS REPLACEMENT - CONTINUED 0032 00
REMOVAL - CONTINUED
2. Loosen bolts (7 and 8). Tilt idler pulley (9) upward and remove V-belt (6) from idler pulley.
6 7
390-1590
9 8
INSTALLATION
1. Install V-belt (6) on idler pulley (9). Adjust V-belt tension to 130 lb-ft (176 Nm).
2. Tighten bolts (7 and 8).
0032 00-2
TM 5-3800-205-23-1
FAN, ALTERNATOR, AND WATER PUMP DRIVE BELTS REPLACEMENT - CONTINUED 0032 00
3. Install two V-belts (3) on drive pulley (1). Adjust tension of V-belts to 130 lb-ft (176 Nm). Tighten bolts (2 and 4).
1 2 3
390-108
5 4
4. Install fan (WP 0031 00).
END OF WORK PACKAGE
0032 00-3
TM 5-3800-205-23-1
0032 00-4
TM 5-3800-205-23-1
ELECTRICAL GENERAL MAINTENANCE INSTRUCTIONS 0033 00
Multiple-Pin Connector Identification Diagrams Splicing Wires

Connector Repair Electrical Ground Points
Sealed Connector Repair Multimeter Usage
Receptacle Connector Repair Relay Inspection and Test
Waterproof Connector Repair Air Intake Heater-to-Engine Ground Strap Replacement
Military Connector Repair Starter Ground Cable Replacement
Ring Terminal Repair Cab-to-Frame Ground Strap Replacement
INITIAL SETUP

Unit Grease, electrically conductive (Item 17, WP
0171 00)
Tool kit, general mechanic’s (Item 33, WP 0172 Insulating varnish, electrical (Item 19, WP 0171
00) 00)
Shop equipment, common no. 1 (Item 24, WP Insulating sleeving (Item 20, WP 0171 00)
0172 00)
Heater, gun type, electric (Item 14, WP 0172 00)
References
Materials/Parts
Cloth, abrasive (Item 7, WP 0171 00) TM 5-3800-205-10-1
Detergent (Item 11, WP 0171 00) TM 5-3800-205-10-2
NOTE
• Use electrically conductive grease on unprotected (exposed to weather) electrical connectors before
connections are made.
• Use electrical insulating varnish on all electrical connections that are mounted outside of machine and
are exposed to harsh weather and/or road spray.
0033 00-1
TM 5-3800-205-23-1
ELECTRICAL GENERAL MAINTENANCE INSTRUCTIONS - CONTINUED 0033 00
MULTIPLE-PIN CONNECTOR IDENTIFICATION DIAGRAMS
NOTE
The following diagrams illustrate typical multiple-pin connectors and identify pin numbers as viewed from
wire side of connector.
390-1189
390-1048
390-1049
390-1190
0033 00-2
TM 5-3800-205-23-1
CONNECTOR REPAIR
NOTE
• Perform the following steps for each wire of connector.
• Tag wires to aid in installation.
1. Using pin removal tool, position tool over pin (1) and push inward to retract two barbs of pin.
2. Remove wire (3) with pin (1) attached, from rear of connector (2).
3. If defective, remove pin (1) from wire (3) by cutting through wire just behind pin.
390-1191
NOTE
Perform steps 4 through 6 only if pin was removed.
4. Using wire stripping tool, strip insulation of wire (3) to expose proper length of metal strands (6).
5. Using crimping tool, securely crimp tabs (5) of pin (1) over metal strands (6) of wire (3).
NOTE
The other two tabs of pin may need to be crimped slightly in order to enter connector.
6. Using crimping tool, crimp tabs (4) at rear of pin (1) over insulation of wire (3).
3 4
5 6 1
390-1192
7. Push pin (1) into rear of connector (2) until fully seated.
0033 00-3
TM 5-3800-205-23-1
SEALED CONNECTOR REPAIR
1. Open hinged cover (14) of connector (13) for access to rear of connector.
NOTE
2. Using pin removal tool, position tool over pin (12) and push inward to retract two barbs of pin.
3. Remove wire (7), with pin (12) and seal (9) attached, from rear of connector (13).
4. If defective, remove pin (12) and seal (9) from wire (7) by cutting through wire just behind seal.
7
8
9
10
11
12 13
14
390-1193
NOTE
Perform steps 5 through 8 only if pin and seal were removed.
5. Position new seal (9) on wire (7).

6. Using wiring stripping tool, strip insulation of wire (7) to expose 1/8 in. (3 mm) length of metal strands (8).
7. Using crimping tool, securely crimp tabs (11) of pin (12) over metal strands (8) of wire (7).
8. Slide seal (9) next to pin (12) and crimp tabs (10) of pin over end of seal.
10. Close hinged cover (14) of connector (13).
RECEPTACLE CONNECTOR REPAIR
1. Using removal tool, insert tool into front of connector (15) and depress locking tab of receptacle (20).
2. Push wire (16), with receptacle (20) attached, through front of connector (15).
3. If defective, remove receptacle (20) from wire (16) by cutting through wire just behind receptacle.
0033 00-4
TM 5-3800-205-23-1
RECEPTACLE CONNECTOR REPAIR - CONTINUED
NOTE
Perform steps 4 through 7 only if receptacle was removed.
4. Slide connector (15) back on wire (16).
15
16
17 18
19 20
390-1194
5. Using wire stripping tool, strip insulation of wire (16) to expose ¼ in. (6 mm) length of metal strands (17).
6. Using crimping tool, securely crimp tabs (19) of receptacle (20) over metal strands (17).
7. Using crimping tool, crimp tabs (18) of receptacle (20) over insulation of wire (16).
8. Slide connector (15) forward over receptacle (20) until locking tab of receptacle snaps into place.
WATERPROOF CONNECTOR REPAIR
1. Remove end cover (27) and gasket (26) from front of connector (25).
2. Remove seal (21) from rear of connector (25) and slide seal back on wire (22).
21 25
22 23 24 26
27
390-1195
NOTE
3. Using pin removal tool, insert tool into front of connector (25) and depress locking tab of connector.
4. Remove wire (22) with pin (24) from rear of connector (25).
5. If defective, remove pin (24) from wire (22) by cutting through wire just behind pin.
0033 00-5
TM 5-3800-205-23-1
WATERPROOF CONNECTOR REPAIR - CONTINUED
NOTE
Perform steps 6 through 9 only if pin was removed.
6. Using wire stripping tool, strip insulation of wire (22) to expose ¼ in. (6 mm) length of metal strands (23).
7. Insert metal strands (23) of wire (22) fully into rear of pin (24).
8. Using crimping tool, securely crimp pin (24) to metal strands (23) of wire (22).
10. Install seal (21) on rear of connector (25).
11. Install gasket (26) and end cover (27) on front of connector (25).
21 25
22 23 24 26
27
390-1195
MILITARY CONNECTOR REPAIR

1. Slide shell (28) back on wire (29) to expose sleeve (32).
2. Remove sleeve (32) from terminal (31) by pulling sleeve forward.
3. If defective, remove terminal (31) from wire (29) by cutting through wire just behind terminal.
32
31
28
29 30
390-1196
NOTE
Perform steps 4 through 6 only if terminal was removed.
4. Using wire stripping tool, strip insulation of wire (29) to expose length of metal strands (30) equal to depth of terminal
(31).
5. Using crimping tool, securely crimp terminal (31) to metal strands (30) of wire (29).
6. Install sleeve (32) to terminal (31) by pushing sleeve over front of terminal until fully seated.
7. Slide shell (28) up wire (29) and over sleeve (32).
0033 00-6
TM 5-3800-205-23-1
RING TERMINAL REPAIR

1. Remove ring terminal (38) from wire (34) by cutting through wire just behind heat shrink tubing (33).
2. Cut heat shrink tubing (33) to length sufficient to cover tabs (36 and 37) of ring terminal (38) and ¼ in. (6 mm) of wire
(34).
3. Slide heat shrink tubing (33) back on wire (34).
4. Using wire stripping tool, strip insulation of wire (34) to expose proper length of metal strands (35).
5. Using crimping tool, securely crimp tabs (37) of ring terminal (38) over metal strands (35).
6. Using crimping tool, crimp tabs (36) of ring terminal (38) over insulation of wire (34).
7. Slide heat shrink tubing (33) over tabs (36 and 37) of ring terminal (38).
8. Use a heat gun to apply heat to heat shrink tubing (33) until tubing snugly conforms to ring terminal (38) and insulation
of wire (34).
36 37
33 34 35 38
390-1197
SPLICING WIRES
NOTE
The selection of crimping tool and type of splice connectors is optional. High quality splice connectors can
be expected to last the life of the machine.
1. Inspect each end of wire (39). Trim insulation and metal strands (40) of wire back, as necessary, to ensure integrity of
wire.
2. Using wire stripping tool, strip each end of wire (39) to expose length of metal strands (40) to suit type of splice connec-
tor (41) used.
NOTE
Perform steps 3 and 4 at each end of splice connector.
3. Insert metal strands (40) of wire (39) fully into splice connector (41).
4. Using crimping tool, securely crimp splice connector (41) to metal strands (40) of wire (39).
40 39
41
40
39
390-1198
0033 00-7
TM 5-3800-205-23-1
ELECTRICAL GROUND POINTS

Many electrical problems are the result of poor ground connections. Ensure that ground connections are good by per-
forming the following steps:
WARNING
Although battery disconnect switch must be ON to test electrical circuit voltage, turn battery disconnect
switch to OFF before performing resistance tests or replacing parts. Failure to follow this warning may
result in injury to personnel and damage to parts or equipment.
a. Remove screw, lockwasher, nut, etc. connecting ground wire terminal to machine ground point.
b. If necessary, clean mounting hardware, wire terminal, and ground point with detergent and a scrub brush.
c. Remove any rust or corrosion from ground point with a wire brush and abrasive cloth.
d. Replace defective mounting hardware and wire terminal as necessary.
e. Install wire terminal to ground point with screw, lockwasher, nut, etc. and tighten securely.
MULTIMETER USAGE
1. General. A multimeter is used to troubleshoot the electrical system of the machine. The multimeter ohms scale is used
to test for continuity, shorts, and resistance. The multimeter voltmeter scale is used to test voltage levels at any point in
the electrical system.
2. Continuity Tests. Continuity tests are performed to check for breaks in a circuit (such as a fuse, switch, light bulb con-
nector or electrical wiring).
NOTE
If readout will not zero properly, replace batteries and repeat zeroing procedure. If readout will not zero after
batteries have been replaced, notify your supervisor.
a. Zero Multimeter.
(1) Set multimeter to ON.
(2) Select OHMS.
(3) Select LOWEST VOLTAGE/OHMS scale.
(4) Touch black and red probes together and check for a zero indication on digital readout.
CAUTION
Before performing a continuity test, always place battery disconnect switch in OFF position and disconnect
circuit to be tested. Failure to follow this caution may damage multimeter.
b. Testing for Continuity.
(1) Zero multimeter.
(2) Connect black and red probes to both terminals of circuit being tested.
(3) Observe readout and interpret results as follows:
(a) If readout indicates 0 (zero), circuit has continuity.
(b) If readout indicates resistance, circuit is open.
0033 00-8
TM 5-3800-205-23-1
MULTIMETER USAGE - CONTINUED
CAUTION
c. Testing for Shorts. A short (or short circuit) occurs when two circuits that should not be connected have metal-to-
metal contact with each other. A short also occurs when a circuit that should not touch ground has metal-to-metal
contact with ground.
(2) Connect black probe to one pin and red probe to either ground or another pin.
(3) Observe readout and interpret results as follows:
(a) If readout indicates 0 (zero), circuits are shorted or circuit is grounded, if testing to ground.
(b) If readout does not indicate 0 (zero), circuits are not shorted.
(c) If readout jumps or flickers, circuits are shorted or grounded intermittently.
CAUTION
d. Testing for Resistance. Allowable resistance readings depend on circuit being tested. Refer to the particular sec-
tion dealing with that circuit or component for allowable readings.
(2) Select OHMS.
(3) Select LOWEST VOLTAGE/OHMS range. If test specifies ohms range, select required range.
(4) Connect black and red probes across circuit to be tested.
(5) Observe readout and interpret results as circuit resistance.
3. Measuring DC Voltage.
a. Set multimeter to ON.
b. Select VOLTS.
c. Select volts DC.
d. Select LOWEST VOLTAGE/OHMS range for voltage range that is higher than volts to be measured.
e. Connect red probe to positive (+) pin and black probe to negative (-) pin.
f. Observe readout and interpret results as DC voltage in circuit being tested.
0033 00-9
TM 5-3800-205-23-1
RELAY INSPECTION AND TEST
1. Inspecting Relays.
a. Check for bent or damaged pins.
b. Check for burned or damaged relay case.
2. Testing Relays.
NOTE
When testing relays, always refer to the circuit diagram printed or stamped on relay case.
a. Using a multimeter, check for continuity across relay coil.

b. Using a multimeter, check open or closed contacts within relay.
AIR INTAKE HEATER-TO-ENGINE BLOCK GROUND STRAP REPLACEMENT
1. Place battery disconnect switch in OFF position (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).

2. Open engine access door (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).
3. Remove two nuts (45), washers (46), and ground strap (44) from studs (47) on intake heater (43) and engine block (42).
NOTE
Ensure ground points are clean.
4. Install ground strap (44) on studs (47) on intake heater (43) and engine block (42) with two washers (46) and nuts (45).
47
390-1688
45,46 44 43 42
0033 00-10
TM 5-3800-205-23-1
STARTER GROUND CABLE REPLACEMENT

3. Remove screw (48), washer (49), and ground cable (50) from ground lug (51).
4. Remove nut (52), lockwasher (53), and other end of

ground cable (50) from starter terminal (54). Discard
lockwasher.
NOTE
Ensure ground points are clean and free of
paint.
5. Install ground cable (50) on starter terminal (54) with
new lockwasher (53) and nut (52).
6. Install other end of ground cable (50) on ground lug
(51) with washer (49) and screw (48).
7. Close engine access door (TM 5-3800-205-10-1 or
TM 5-3800-205-10-2). 390-1870
48,49
50,51 50,52
53,54
CAB-TO-FRAME GROUND STRAP REPLACEMENT

NOTE
Cab-to-frame ground strap is located below cab and to the rear of seat on left side.
2. Remove screw (55), washer (56), and ground strap (58) from cab ground lug (57).
55,56,57
58
59,60,61
390-1304
0033 00-11
TM 5-3800-205-23-1
CAB-TO-FRAME GROUND STRAP REPLACEMENT - CONTINUED

3. Remove screw (59), washer (60), and other end of ground strap (58) from frame ground lug (61).
NOTE
Ensure ground points are cl3ean and free of paint.
4. Install ground strap (58) on frame ground lug (61) with washer (60) and screw (59).
5. Install other end of ground strap (58) to cab ground lug (57) with washer (56) and screw (55).
55,56,57
58
59,60,61
390-1304
END OF WORK PACKAGE
0033 00-12
TM 5-3800-205-23-1
ALTERNATOR REPLACEMENT 0034 00
INITIAL SETUP
Maintenance Level References - Continued

Unit WP 0032 00
Tool kit, general mechanic’s (Item 33, WP 0172 00) Machine parked on hard, level surface (TM 5-3800-
205-10-1 or TM 5-3800-205-10-2)
Materials/Parts Scraper bowl or water tank lowered to ground (TM
Strap, tiedown (Item 38, WP 0171 00) 5-3800-205-10-1 or TM 5-3800-205-10-2)
5-3800-205-10-2)
Personnel Required Wheels chocked (TM 5-3800-205-10-1 or TM 5-
Two 3800-205-10-2)
References or TM 5-3800-205-10-2)
WP 0005 00 Battery cables disconnected (WP 0067 00)
REMOVAL
NOTE
• Remove tiedown straps as needed and discard. Use new tiedown straps on installation.
1. Remove two nuts (3) from bolts (4) on alternator (1). 1 2
2. Pull out, but do not remove, bolts (4) and washers (5)
approximately 1/2 in. (13 mm) and remove alternator
belt guard (2).
3,4,5
(HIDDEN)
0034 00-1
TM 5-3800-205-23-1
ALTERNATOR REPLACEMENT - CONTINUED 0034 00
REMOVAL - CONTINUED
3. Pull back rubber cap (6) and remove nut (7), washer 6 7,8 9,10
(8), and wire terminal (15) from terminal (16).
4. Disconnect wire (9) from terminal (10).
16
5. Remove nut (11), washer (12), and wire terminal
(14) from terminal (13).
15
14 13 11,12
6. Remove bolt (4), washer (5), and alternator adjust-

ing bracket (17) from alternator (1) and support arm 19
5 17 18
(18).
7. Tilt alternator (1) toward engine and remove two
drive belts (19) from alternator pulley (20). 4
20
0034 00-2
TM 5-3800-205-23-1
REMOVAL - CONTINUED
WARNING
Use extreme caution when handling heavy parts. Provide adequate support and use assistance during
procedure. Failure to follow this warning may result in injury to personnel.
NOTE
Alternator weighs 32 lb (15 kg).
8. With assistant holding alternator (1), remove washer 5

(5), bolt (4) and remove alternator (1) from mount-
ing bracket (21).
4
21
INSTALLATION
WARNING
NOTE
Alternator weighs 32 lb (15 kg).
1. With assistance, position alternator (1) on mounting bracket (21) and install bolt (4) and washer (5) approximately
1/2 in. (13 mm).
2. Tilt alternator (1) towards engine and install two drive belts (19) on pulley (20).
3. Position alternator (1) and adjusting bracket (17) on support arm (18) and install bolt (4) and washer (5) approxi-
mately 1/2 in. (13 mm).
0034 00-3
TM 5-3800-205-23-1
4. Install wire terminal (14) on terminal (13) with washer 6 7,8 9,10
(12) and with nut (11).
5. Connect wire terminal (9) to terminal (10).
16
6. Install wire terminal (15) on terminal (16) with washer
(8) and nut (7).
7. Install rubber cap (6) on terminal (16).
15
14 13 11,12
NOTE
Install nuts loosely.
8. Install alternator belt guard (2) on alternator (1) with 1 2
two bolts (4) and nuts (3).
3,4,5
(HIDDEN)
9. Adjust drive belts (WP 0032 00).

10. Connect battery cables (WP 0067 00).
11. Test alternator (WP 0005 00).
0034 00-4
TM 5-3800-205-23-1
WARNING
If machine is parked indoors, DO NOT run engine unless exhaust fumes are vented to the outside. Fail-
ure to follow this warning may cause injury or death due to carbon monoxide poisoning.
13. Start engine (TM 5-3800-205-10-1 or TM 5-3800-205-10-2) and verify operation of alternator.
END OF WORK PACKAGE
0034 00-5
TM 5-3800-205-23-1
0034 00-6
TM 5-3800-205-23-1
STARTER REPLACEMENT 0035 00
INITIAL SETUP
Maintenance Level Personnel Required

Unit Two

Tool kit, general mechanics’s (Item 33, WP 0172 Battery cables disconnected (WP 0067 00)
00) Center guard plates removed (WP 0100 00)
Materials/Parts
Gasket
REMOVAL
1. Remove two bolts (1) and washers (2) from plate (3). 1,2
Move plate aside.
390-933
0035 00-1
TM 5-3800-205-23-1
STARTER REPLACEMENT - CONTINUED 0035 00
REMOVAL - CONTINUED
NOTE
Tag all wires and cable assemblies to aid in installation.
2. Remove nut (4), washer (5), and four cables (6) from starter (7).
3. Remove nut (9), washer (10) and three cables (8) from solenoid (11).
4,5 6 8
9,10
7 11
WARNING
NOTE
Starter weighs 57 lb (26 kg).
4. With assistance, remove three bolts (13), starter (7),

and gasket (12) from machine. Discard gasket.
7
13 12 (HIDDEN)
0035 00-2
TM 5-3800-205-23-1
STARTER REPLACEMENT - CONTINUED 0035 00
INSTALLATION
WARNING
NOTE
Starter weighs 57 lb (26 kg).
1. With assistance, install new gasket (12) and starter (7) on machine with three bolts (13).
2. Install three cables (8) on solenoid (11) with washer (10) and nut (9).
3. Install four cables (6) on starter (7) with washer (5) and nut (4).
4. Install plate (3) with two bolts (1) and washers (2). 1,2

END OF WORK PACKAGE
0035 00-3
TM 5-3800-205-23-1
0035 00-4
TM 5-3800-205-23-1
BACKUP ALARM SWITCH REPLACEMENT 0036 00

INITIAL SETUP

205-10-1 or TM 5-3800-205-10-2)
Tools and Special Tools Scraper bowl or water tank lowered to ground (TM
5-3800-205-10-1 or TM 5-3800-205-10-2)
00)
5-3800-205-10-2)
Materials/Parts Wheels chocked (TM 5-3800-205-10-1 or TM 5-
3800-205-10-2)
Strap, tiedown (Item 38, WP 0171 00)
Pin, spring (3) 3800-205-10-1 or TM 5-3800-205-10-2)
REMOVAL
1. Remove spring pin (1) and neutral lock lever (2) from panel (11). Discard spring pin.
2. Remove spring pin (3), parking brake handle (4), and nut (12) from valve (13). Discard spring pin. Discard nut if seal is
cracked or damaged.
3. Remove spring pin (5), emergency brake handle (6), and nut (10) from valve (7). Discard spring pin. Discard nut if seal
is cracked or damaged.
4. Remove four screws (8) and washers (9) from panel (11).
NOTE
Panel does not have to be completely removed to access backup alarm switch.
5. Slide panel (11) up transmission shift lever (14) and turn panel to left.
3 4 5 6
8,9
1
10
14
13 12 11
0036 00-1
TM 5-3800-205-23-1
BACKUP ALARM SWITCH REPLACEMENT - CONTINUED 0036 00
REMOVAL - CONTINUED
6. Mark outline of backup alarm switch (15) on bracket (21).
NOTE
Remove tiedown straps as needed and discard. Use new tiedown straps on installation.
7. Remove two screws (16), washers (17), nuts (18), and backup alarm switch (15) from bracket (21).
8. Remove 114 red lead (19) from COMMON terminal (20).
9. Remove 321 brown lead (22) from OPEN terminal (23).
15 16,17,18 19,20 21
22,23
INSTALLATION
1. Install 321 brown lead (22) on OPEN terminal (23).

2. Install 114 red lead (19) on COMMON terminal (20).
3. Install backup alarm switch (15) on bracket (21) with two screws (16), washers (17), and nuts (18).
4. Install panel (11) with four washers (8) and screws (7).
5. Install nut (10) on valve (7).
6. Install emergency brake handle (6) on valve (7) with new spring pin (5).
8. Install parking brake handle (4) on valve (13) with new spring pin (3).
9. Install neutral lock lever (2) on panel (11) with new spring pin (1).
0036 00-2
TM 5-3800-205-23-1
BACKUP ALARM SWITCH REPLACEMENT - CONTINUED 0036 00
3 4 5 6
8,9
1
10
14
13 12 11
END OF WORK PACKAGE
0036 00-3
TM 5-3800-205-23-1
0036 00-4
TM 5-3800-205-23-1
BATTERY DISCONNECT SWITCH REPLACEMENT 0037 00
INITIAL SETUP

205-10-1 or TM 5-3800-205-10-2)
00) Parking brake applied (TM 5-3800-205-10-1 or TM
5-3800-205-10-2)
Materials/Parts
Tag, marker (Item 39, WP 0171 00) 3800-205-10-2)
Lockwasher (4) Battery cables disconnected (WP 0067 00)
REMOVAL
1. Remove key (1) from switch (2).
1 2
0037 00-1
TM 5-3800-205-23-1
BATTERY DISCONNECT SWITCH REPLACEMENT- CONTINUED 0037 00
REMOVAL - CONTINUED
NOTE
Tag cables to aid in installation.
2. Pull rubber boots (3) from terminals (4 and 12). 3 4 5,6 7 8,9 10,11 12 3
3. Remove nut (5), lockwasher (6), and cable lead (7)
from left terminal (4). Discard lockwasher.
4. Remove nut (8), lockwasher (9), cable lead (10), and
electrical lead (11) from right terminal (12). Discard
lockwasher.
NOTE
There is another lockwasher (14) located between plate and switch.
5. Remove nut (13) and lockwasher (14) from switch (2). 1 2

Discard lockwasher.
6. Remove plate (15), lockwasher (14), and switch (2)
from mounting bracket (16). Discard lockwasher.
7. Inspect plate (15) for damage. Replace plate if dam-
aged.
16 14,15 13,14
0037 00-2
TM 5-3800-205-23-1
BATTERY DISCONNECT SWITCH REPLACEMENT- CONTINUED 0037 00
INSTALLATION
1. Install new lockwasher (14) on switch (2).
NOTE
Align switch guide pin with hole in mounting bracket when installing switch.
2. Position switch (2) on mounting bracket (16).

3. Install plate (15) on mounting bracket (16) with new lockwasher (14) and nut (13).
4. Install electrical lead (11) and cable lead (10) on right terminal (12) with new lockwasher (9) and nut (8).
5. Install cable lead (7) on left terminal (4) with new lockwasher (6) and nut (5).
6. Install rubber boots (3) over terminals (4 and 12).
7. Install key (1) in switch (2).
END OF WORK PACKAGE
0037 00-3
TM 5-3800-205-23-1
0037 00-4
TM 5-3800-205-23-1
CIRCUIT BREAKERS REPLACEMENT 0038 00
60-Amp Circuit Breaker: Removal, Installation

INITIAL SETUP

00) 205-10-1 or TM 5-3800-205-10-2)
5-3800-205-10-1 or TM 5-3800-205-10-2)
0172 00)
Tag, marker (Item 39, WP 0171 00) Wheels chocked (TM 5-3800-205-10-1 or TM 5-
3800-205-10-2)
Lockwasher (as required)
Starwasher (as required) 3800-205-10-1 or TM 5-3800-205-10-2)
60-AMP CIRCUIT BREAKER REMOVAL

1. Remove nine screws (7) from right panel (6).
2. Slide cable (8) from grommet (9) and remove panel (6).
3. Remove three top screws (4) and two brackets (5) from switch panel (2).
4. Remove five screws (1) and top access panel (3).
2 3 4,5 6 7
1
8,9
390-1221
0038 00-1
TM 5-3800-205-23-1
CIRCUIT BREAKERS REPLACEMENT - CONTINUED 0038 00
60-AMP CIRCUIT BREAKER REMOVAL - CONTINUED

5. Remove three bolts (10) and washers (11) from fuse/circuit breaker panel (15).
6. Remove cable and clamp (12) from left side of fuse/circuit breaker panel (15).
NOTE
Note orientation of plate prior to removing circuit breaker.
7. Remove two screws (16), plate (13), and circuit breaker (14) from fuse/circuit breaker panel (15).
12 13,14 15
10,11
16
NOTE
Tag leads to aid in installation.
8. Remove nut (17), washer (18), two leads (19), and lockwasher (20) from left terminal (21). Discard lockwasher.
9. Remove nut (22), washer (23), lockwasher (24), and lead (25) from right terminal (26). Discard lockwasher.
17,18,19,20,21
22,23,24
25,26
0038 00-2
TM 5-3800-205-23-1
60-AMP CIRCUIT BREAKER INSTALLATION

1. Install lead (25), new lockwasher (24), washer (23), and nut (22) on right terminal (26). Tighten nut to 9 lb-in. (1 Nm).
2. Install new lockwasher (20), two leads (19), washer (18), and nut (17) on left terminal (21). Tighten nut to 9 lb-in. (1
Nm).
3. Install plate (13) and circuit breaker (14) on fuse/circuit breaker panel (15) with two screws (16).
4. Position cable and clamp (12) on left side of fuse/circuit breaker panel (15).
5. Install panel (15) with three bolts (10) and washers (11).
6. Install top access panel (3) and with five screws (1).
7. Install top three bolts (4) and two brackets (5) on switch panel (2).
8. Slide cable (8) into grommet (9) on right panel (6).
9. Install right panel (6) with nine screws (7).
2 3 4,5 6 7
1
8,9
390-1221
0038 00-3
TM 5-3800-205-23-1

1. Perform steps 1 through 5 of 60-Amp Circuit Breaker Removal.
NOTE
27 28 29 15
NOTE
3. Remove two screws (30), starwashers (31), and leads (32) from terminals (33). Discard starwashers.
30,31 32,33
0038 00-4
TM 5-3800-205-23-1

1. Install two screws (30), new starwashers (31), and leads (32) on terminals (33).
3. Perform steps 4 through 9 of 60-Amp Circuit Breaker Installation.
NOTE
34 35 15
36
NOTE
37,38 39,40
0038 00-5
TM 5-3800-205-23-1

37,38 39,40
34 35 15
36
0038 00-6
TM 5-3800-205-23-1
NOTE
There are two 15-amp circuit breakers used.

2. Remove two screws (41), washers (42), and circuit breaker (43) from fuse/circuit breaker panel (15).
41,42,43 15
NOTE
44,45
46,47
44,45
46,47
0038 00-7
TM 5-3800-205-23-1
15-AMP CIRCUIT BREAKERS INSTALLATION

44,45
46,47
44,45
46,47
5. Install two screws (41), washers (42), and circuit breaker (43) on fuse/circuit breaker panel (15).
41,42,43 15
END OF WORK PACKAGE
0038 00-8
TM 5-3800-205-23-1
EMS PANEL REPLACEMENT 0039 00
INITIAL SETUP

5-3800-205-10-1 or TM 5-3800-205-10-2)
00)
205-10-1 or TM 5-3800-205-10-2) 3800-205-10-1 or TM 5-3800-205-10-2)
REMOVAL
2. Remove screw (4) and bracket (5) from switch panel (6).
3. Remove panel (3) from enclosure (7).
1,2 3
390-001
0039 00-1
TM 5-3800-205-23-1
EMS PANEL REPLACEMENT - CONTINUED 0039 00
REMOVAL - CONTINUED
4. Disconnect harness connector (9) from EMS connector (8).
NOTE
Instrument panel shown removed for clarity.
5. Remove four nuts (10), washers (11), and two cable clamps (12) from EMS (13).
6. Remove bolt (14), washer (15), and lower bracket (16) from EMS (13).
7. Remove EMS (13) from panel (3).
10,11 12
13
14,15
16
0039 00-2
TM 5-3800-205-23-1
EMS PANEL REPLACEMENT - CONTINUED 0039 00
INSTALLATION
1. Position EMS (13) on panel (3) and install lower bracket (16) with washer (15) and bolt (14).
2. Install two cable clamps (12), from washers (11), and nuts (10) on EMS (13).
3. Connect harness connector (9) to EMS connector (8).
4. Position panel (3) in enclosure (7) and install bracket (5) with screw (4).
5. Install four screws (1) and washers (2) on panel (3).
1,2 3
390-001
END OF WORK PACKAGE
0039 00-3
TM 5-3800-205-23-1
0039 00-4
TM 5-3800-205-23-1
FUSE REPLACEMENT 0040 00
INITIAL SETUP

5-3800-205-10-1 or TM 5-3800-205-10-2)
00)
205-10-1 or TM 5-3800-205-10-2) 3800-205-10-1 or TM 5-3800-205-10-2)
REMOVAL
1. Remove cover (1) from fuse/circuit breaker panel (2).
2. Remove failed fuse (3).

EJECTOR WORK LIGHT
CONTROL WATER GAGES FRONT
LEVER DISTRIBUTOR AND EMS WIPER
1 2
FUEL HORN/BACKUP
PUMP ALARM
0040 00-1
TM 5-3800-205-23-1
FUSE REPLACEMENT - CONTINUED 0040 00
INSTALLATION
1. Install new fuse (3).
2. Install cover (1) on fuse/circuit breaker panel (2).
EJECTOR WORK LIGHT

CONTROL WATER GAGES FRONT
LEVER DISTRIBUTOR AND EMS WIPER
1 2
FUEL HORN/BACKUP
PUMP ALARM
END OF WORK PACKAGE
0040 00-2
TM 5-3800-205-23-1
HAZARD FLASHER UNIT REPLACEMENT 0041 00
INITIAL SETUP

5-3800-205-10-1 or TM 5-3800-205-10-2)
00)
Tag, marker (Item 39, WP 0171 00) Battery disconnect switch in OFF position (TM 5-
3800-205-10-1 or TM 5-3800-205-10-2)
Equipment Condition
205-10-1 or TM 5-3800-205-10-2)
REMOVAL
1. Remove two screws (1), washers (2), bracket (3), and cable clamps from steering column (4).
1,2
(HIDDEN)
0041 00-1
TM 5-3800-205-23-1
HAZARD FLASHER UNIT REPLACEMENT - CONTINUED 0041 00
REMOVAL - CONTINUED
2. Remove two screws (5) and flasher unit (6) from bracket (3).
3. Tag electrical leads (7) and disconnect from flasher unit (6).
5 3
INSTALLATION
1. Connect leads (7) to flasher unit (6).
2. Install flasher unit (6) on bracket (3) with two screws
(5).
3. Install bracket (3) and cable clamps on steering col-
umn (4) with two washers (2) and screws (1). 1,2
(HIDDEN)
END OF WORK PACKAGE
0041 00-2
TM 5-3800-205-23-1
INSTRUMENT PANEL GAGES AND BULBS REPLACEMENT 0042 00
Instrument Panel: Removal, Installation Instrument Panel Gages and Bulbs: Removal, Installa-
tion
INITIAL SETUP

00) 5-3800-205-10-2)
Tape, antiseizing (Item 40, 0171 00) Battery disconnect switch in OFF position (TM 5-
Machine parked on hard, level surface (TM 5-3800- Air tanks drained (TM 5-3800-205-10-1 or TM 5-
205-10-1 or TM 5-3800-205-10-2) 3800-205-10-2)
INSTRUMENT PANEL REMOVAL

1. Remove four screws (1) and washers (2) from panel 1,2 3 4
(3).
2. Remove screw (4) and bracket (6) from switch panel
(5).
3. Pull panel (3) from enclosure (7). 5
0042 00-1
TM 5-3800-205-23-1
INSTRUMENT PANEL GAGES AND BULBS REPLACEMENT- CONTINUED 0042 00
INSTRUMENT PANEL REMOVAL - CONTINUED 8 9

4. Disconnect harness connector (8) from EMS connec-
tor (9).
WARNING
5. Disconnect air hose (10) from elbow (11) on air pres- 11
12
sure gage (12).
6. Remove antiseizing tape from threads of elbow (11). 10
0042 00-2
TM 5-3800-205-23-1
INSTRUMENT PANEL INSTALLATION

1. Apply antiseizing tape to male threads of elbow (11). 1,2 3 4
2. Connect air hose (10) to elbow (11) on air pressure
gage (12).
3. Connect harness connector (8) to EMS connector (9).
4. Position panel (3) in enclosure (7). 5
5. Install four screws (1) and washers (2) in panel (3).
6. Install screw (4) and bracket (6) on switch panel (5).
0042 00-3
TM 5-3800-205-23-1
INSTRUMENT PANEL GAGES AND BULBS REMOVAL
NOTE
• Tachometer, alert indicator, speedometer, coolant temperature gage, oil temperature gage, air pressure
gage, and fuel quantity gage are removed the same way. Speedometer (18) is shown.
• If removing air pressure gage, ensure that air tanks are drained before disconnecting air hose.
• Panel is shown removed for clarity.
• Tag leads to aid in installation.
1. Loosen, but do not remove, three nuts (12) and lockwashers (13).
2. Remove three leads (14).
3. Remove socket (16) with bulb (17) from speedometer (18).
4. Remove bulb (17) from socket (16).
5. Remove two nuts (19) and washers (20) from bracket (15).
6. Remove bracket (15) from speedometer (18).
7. Remove speedometer (18) from panel (3).
12,13,14 15 16,17 ALERT INDICATOR

18
TACHOMETER
16
17
19,20 3
OIL
TEMP-
ERATURE
GAGE
COOLANT
AIR PRESSURE TEMPERATURE
FUEL QUANTITY
GAGE GAGE
GAGE
0042 00-4
TM 5-3800-205-23-1
INSTRUMENT PANEL GAGES AND BULBS INSTALLATION
NOTE
• Tachometer, alert indicator, speedometer, coolant temperature gage, oil temperature gage, air pressure
gage, and fuel quantity gage are installed the same way. Speedometer (18) is shown.
• If installing air pressure gage, ensure antiseizing tape is used on elbow threads prior to connection of air
hose.
• Panel is shown removed for clarity.
1. Position speedometer (18) in panel (3) and install bracket (15) with two washers (20) and nuts (19).
2. Position three leads (14) under lockwashers (13) and tighten nuts (12).
3. Install bulb (17) in socket (16).
4. Install socket (16) with bulb (17) in speedometer (18).
END OF WORK PACKAGE
0042 00-5
TM 5-3800-205-23-1
0042 00-6
TM 5-3800-205-23-1
KEY START SWITCH REPLACEMENT 0043 00
INITIAL SETUP

205-10-1 or TM 5-3800-205-10-2)
5-3800-205-10-1 or TM 5-3800-205-10-2)
00) Parking brake applied (TM 5-3800-20510-1 or TM
5-3800-205-10-2)
3800-205-10-2)
Lockwasher 3800-205-10-1 or TM 5-3800-205-10-2)
REMOVAL
1. Remove six screws (2) and two brackets (3) from switch panel (4).
2. Remove key (6) from key start switch (5).
3. Remove bezel nut (1) from key start switch (5) and pull switch through back of switch panel (4).
1 2,3
4
5
0043 00-1
TM 5-3800-205-23-1
KEY START SWITCH REPLACEMENT - CONTINUED 0043 00
REMOVAL - CONTINUED
NOTE
Tag all wires to aid in installation.
4. Disconnect cable connector (10) from switch connector (11).

5. Remove screw (7), lockwasher (8), wires, and ground cable (9) from key start switch (5). Discard lockwasher.
10,11
5 7,8,9
INSTALLATION
NOTE
When installing wire leads, insert leads between screw and lockwasher.
1. Install wires and ground cable (9) on key start switch (5) with new lockwasher (8) and screw (7).
2. Connect cable connector (10) to switch connector (11).
3. Position key start switch (5) through back of switch panel (4) and install bezel nut (1).
4. Install six screws (2) and two brackets (3) on switch panel (4).
5. Insert key (6) in key start switch (5).
0043 00-2
TM 5-3800-205-23-1
KEY START SWITCH REPLACEMENT - CONTINUED 0043 00
1 2,3
4
5
END OF WORK PACKAGE
0043 00-3
TM 5-3800-205-23-1
0043 00-4
TM 5-3800-205-23-1
LIGHT SWITCH AND GROUND CABLE REPLACEMENT 0044 00
INITIAL SETUP

Unit
Tool kit, general mechanic’s (Item 33, WP 0172 00)
Materials/Parts 5-3800-205-10-1 or TM 5-3800-205-10-2)
Lockwasher
5-3800-205-10-2)

3800-205-10-2)

3800-205-10-1 or TM 5-3800-205-10-2)
REMOVAL
1. Remove four screws (1) and bracket (2) from dash (3). 1 2
2. Remove four screws (4), washers (5), and switch (6) 3
from bracket (2).
6 4,5
0044 00-1
TM 5-3800-205-23-1
LIGHT SWITCH AND GROUND CABLE REPLACEMENT - CONTINUED 0044 00
REMOVAL - CONTINUED
7 8
6
3. Remove cable connector (7) from switch connector
(8). 2
4. Remove screw (9), lockwasher (10), and ground cable
(11) from switch (6). Discard lockwasher.
9,10
390-1126
11
5. Remove nine screws (12) and panel (13). 15

12 13 14
6. Remove five screws (14) and panel (15).
390-1221
0044 00-2
TM 5-3800-205-23-1
LIGHT SWITCH AND GROUND CABLE REPLACEMENT - CONTINUED 0044 00
REMOVAL - CONTINUED 16,17 18

7. Remove screw (16), washer (17), and ground cable
(11) from ground lug (18).
390-1128
11
INSTALLATION
1. Ensure that ground lug (18) is clean and install ground cable (11) on ground lug with washer (17) and screw (16).
2. Install panel (15) with five screws (14).
3. Install panel (13) with nine screws (12).
NOTE
Switch connector is master keyed at 6 o’clock position.
4. Align keyways and connect cable connector (7) to switch connector (8).
5. Install ground cable (11) on switch (6) with screw (9) 1 2
and new lockwasher (10). 3
6. Install switch (6) on bracket (2) with four screws (4)
and washers (5).
7. Install bracket (2) on dash (3) with four screws (1).
6 4,5
END OF WORK PACKAGE
0044 00-3
TM 5-3800-205-23-1
This Pages Intentionally Left Blank.
0044 00-4
TM 5-3800-205-23-1
MAIN, FUEL PUMP, START, AND AIR INTAKE HEATER RELAYS REPLACEMENT 0045 00
Main Relay: Removal, Installation

Fuel Pump Relay: Removal, Installation
Start Relay: Removal, Installation
Air Inlet Heater Relay: Removal, Installation
INITIAL SETUP

Unit Machine parked on hard, level ground (TM 5-3800-
205-10-1 or TM 5-3800-205-10-2)
Tool kit, general mechanic’s (Item 33, WP 0172 00) 5-3800-205-10-1 or TM 5-3800-205-10-2)
Tag, marker (Item 39, WP 0171 00) 5-3800-205-10-2)
3800-205-10-2)
3800-205-10-1 or TM 5-3800-205-10-2)
NOTE
This procedure is used to replace main, fuel pump, start, and air intake heater relays.
MAIN RELAY REMOVAL
1. Remove nine screws (1) from panel (2).
2. Remove panel (2).
3. Slide grommet (3) and cable (4) from panel (2).
1 2
3,4
390-1221
0045 00-1
TM 5-3800-205-23-1
MAIN, FUEL PUMP, START, AND AIR INTAKE HEATER RELAYS REPLACEMENT - CONTINUED 0045 00
MAIN RELAY REMOVAL - CONTINUED

4. Remove two screws (5) and washers (6) from relay bracket (7).
NOTE
Tag wires to aid in installation.
5. Remove four nuts (8) and wires (9) from terminals (10) and remove main relay.
MAIN
5,6 7 RELAY
8,9,10
MAIN RELAY INSTALLATION
1. Install wires (9) on terminals (10) with four nuts (8).
2. Secure relay bracket (7) with two screws (5) and washers (6).
3. Slide grommet (3) and cable (4) on panel (2).
4. Secure panel (2) with nine screws (1).
1 2
3,4
390-1221
0045 00-2
TM 5-3800-205-23-1
FUEL PUMP RELAY REMOVAL

NOTE
5. Disconnect black lead (14) from orange and black lead (15).
6. Remove two nuts (16) and wires (17) from terminals (18) and remove fuel pump relay.
FUEL PUMP
11,12 13 RELAY
14
15
16,17,18
FUEL PUMP RELAY INSTALLATION

1. Install wires (17) on terminals (18) with two nuts (16).
3. Connect black lead (14) to orange and black lead (15).
0045 00-3
TM 5-3800-205-23-1
START RELAY REMOVAL

1 2
3,4
390-1221
NOTE
Tag wires to aid in installation
5. Disconnect black leads (22) from green and black leads (23).
6. Remove four nuts (24) and wires (25) from terminals (26) and remove start relay.
19,20 21
START
RELAY
22
24,25,26 23
0045 00-4
TM 5-3800-205-23-1
START RELAY INSTALLATION

1. Install wires (25) on terminals (26) with four nuts (24).
3. Connect black leads (22) to green and black leads (23).
AIR INLET HEATER RELAY REMOVAL
2. Remove two screws (27), washers (28), and relay (29) from firewall.
NOTE
3. Remove two nuts (30) washers (31) and leads (32) from terminals (33).
4. Remove from clip and disconnect relay leads (34) from harness connector leads (35).
27,28 29 AIR INLET

HEATER RELAY
30,31,32,33
35 34
AIR INLET HEATER RELAY INSTALLATION
1. Connect relay leads (34) to harness connector leads (35). Secure leads in clip.
2. Install leads (32) on terminals (33) with two washers (31) and nuts (30).
3. Position relay (29) on firewall and secure with two screws (27) and washers (28).
END OF WORK PACKAGE
0045 00-5
TM 5-3800-205-23-1
0045 00-6
TM 5-3800-205-23-1
NEUTRAL START SWITCHES REPLACEMENT 0046 00
INITIAL SETUP

205-10-1 or TM 5-3800-205-10-2)
5-3800-205-10-1 or TM 5-3800-205-10-2)
5-3800-205-10-2)
3800-205-10-2)
Pin, spring (3) 3800-205-10-1 or TM 5-3800-205-10-2)
REMOVAL
1. Remove spring pin (1) and neutral lock lever (2) from panel (11). Discard spring pin.
2. Remove spring pin (3), parking brake handle (4), and nut (12) from valve (13). Discard spring pin.
3. Remove spring pin (5), emergency brake handle (6), and nut (10) from valve (7). Discard spring pin.
NOTE
Panel does not have to be completely removed to access neutral start switches.
5. Slide panel (11) up transmission shift lever (14) and turn panel to left.
3 4 5 6
8,9
1
10
14
13 12 11
0046 00-1
TM 5-3800-205-23-1
NEUTRAL START SWITCHES REPLACEMENT - CONTINUED 0046 00
REMOVAL - CONTINUED
6. Inspect seal inside nuts (10 and 12) for cracks or dam- 10,12 SEAL
age. Discard nuts if seal is damaged.
7. Mark outline of switch bracket (16) on support (17).

8. Remove two screws (18) and washers (19) from switch bracket (16). Pull bracket from support (17).
9. Remove two screws (20), washers (21), nuts (22), and switches (15) from switch bracket (16).
15 16 17
18,19
20,21,22
NOTE
• Transmission neutral start switch is top switch and EMS neutral switch is bottom switch.
• Perform step 10 for top switch
• Perform step 11 for bottom switch.
• Tag leads to aid in installation.
0046 00-2
TM 5-3800-205-23-1
REMOVAL - CONTINUED
10. Loosen, but do not remove, screw (23) and remove 316 pink lead (24) from OPEN terminal (25).
11. Loosen, but do not remove, screw (26) and remove 307 orange lead (27) from COMMON terminal (28).
12. Loosen, but do not remove, screw (29) and remove 201 black lead (30) from OPEN terminal (31).
13. Loosen, but do not remove, screw (32) and remove 409 orange lead (33) from COMMON terminal (34).
15 16 17
18,19
32,33,34
20,21,22
23,24,25
29,30,31 26,27,28
INSTALLATION
NOTE
• Transmission neutral start switch is top switch and EMS neutral switch is bottom switch.
• Perform step 1 for top switch.
• Perform step 2 for bottom switch.
• Leads must be installed between screw head and starwasher.
1. Install 316 pink lead (24) on OPEN terminal (25) with screw (23).
2. Install 307 orange lead (27) on COMMON terminal (28) with screw (26).
3. Install 201 black lead (30) on OPEN terminal (31) with screw (29).
4. Install 409 orange lead (33) on COMMON terminal (34) with screw (32).
5. Install switches (15) on switch bracket (16) with two screws (20), washers (21), and nuts (22).
NOTE
Switch bracket must be installed on support as marked prior to removal.
6. Install switch bracket (16) on support (17) with two screws (18) and washers (19).
0046 00-3
TM 5-3800-205-23-1
9. Install emergency brake handle (6) on valve (7) with new spring pin (5).
11. Install parking brake handle (4) on valve (13) with new spring pin (3).
12. Install neutral lock lever (2) with new spring pin (1).
3 4 5 6
8,9
1
10
14
13 12 11
13. Perform a functional test of neutral start switches (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).
END OF WORK PACKAGE
0046 00-4
TM 5-3800-205-23-1
PARKING BRAKE AND EMERGENCY BRAKE PRESSURE SWITCHES REPLACEMENT 0047 00
INITIAL SETUP
00) 5-3800-205-10-2)
Tape, antiseizing (Item 40, WP 0171 00) 3800-205-10-2)
Pin, spring (3) Battery disconnect switch in OFF position (TM 5-
Equipment Condition 3800-205 -10-1 or TM 5-3800-205-10-2)
205-10-1 or TM 5-3800-205-10-2) 3800-205-10-2)
NOTE
This work package describes replacement of both parking and emergency brake pressure switches.
REMOVAL
1. Remove spring pins (1) from neutral lock lever (2), parking brake handle (3), and emergency brake handle (4). Discard
spring pins.
2. Remove handles (2, 3, and 4).
3. Remove nuts (5) from valves (6).
1 3 1 4
5
6 5 6
0047 00-1
TM 5-3800-205-23-1
PARKING BRAKE AND EMERGENCY BRAKE PRESSURE SWITCHES

REPLACEMENT- CONTINUED 0047 00
REMOVAL - CONTINUED
4. Inspect seal inside nuts (5) for cracks or damage. If seals are cracked or damaged, replace nuts (5).
5 SEAL
NOTE
Panel does not have to be completely removed to access pressure switches. Slide panel up transmission shift
lever and turn panel to left.
5. Remove four screws (7) and washers (8) from panel (9) and move panel out of the way.
7,8
0047 00-2
TM 5-3800-205-23-1

REMOVAL - CONTINUED
6. Disconnect pressure switch connector (11) from harness connector (12).
7. Remove switch (10) from valve (6).
10
11
12
INSTALLATION
1. Apply antiseizing tape to threads of switch (10).
2. Install switch (10) in valve (6).
3. Connect pressure switch connector (11) to harness connector (12).
4. Position valves (6) through panel (9). Secure panel with four screws (7) and washers (8).
0047 00-3
TM 5-3800-205-23-1

5. Secure valves (6) to panel (9) with nuts (5).
6. Position handles (2, 3, and 4) and install new spring pins (1) in handles.
1 3 1 4
5
6 5 6
WARNING
7. Start engine and fully charge air system (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).
8. Perform a functional check of parking and emergency brake controls (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).
END OF WORK PACKAGE
0047 00-4
TM 5-3800-205-23-1
RELAY REPLACEMENT 0048 00

INITIAL SETUP

5-3800-205-10-1 or TM 5-3800-205-10-2)
00)
205-10-1 or TM 5-3800-205-10-2) 3800-205-10-1 or TM 5-3800-205-10-2)
NOTE
Turn/flash, flood enable, LO/HI beam, horn/backup alarm, and water wagon flood relays are replaced the
same way. Turn/flash relay is shown.
REMOVAL
1. Remove two screws (1) and panel (2) from dash (3).
1 2
0048 00-1
TM 5-3800-205-23-1
RELAY REPLACEMENT - CONTINUED 0048 00
REMOVAL - CONTINUED
2. Remove screw (4) from relay bracket (5).
3. Disconnect electrical connector (6) from relay (7).
5
4 WATER WAGON FLOOD
TURN/FLASH
6
FLOOD HORN/BACKUP
ENABLE LO/HI BEAM
ALARM
INSTALLATION
1. Connect electrical connector (6) to relay (7).
2. Position relay (7) and relay bracket (5) in dash (3) and install screw (4).
0048 00-2
TM 5-3800-205-23-1
RELAY REPLACEMENT - CONTINUED 0048 00
3. Install panel (2) on dash (3) with two screws (1).
1 2
END OF WORK PACKAGE
0048 00-3
TM 5-3800-205-23-1
0048 00-4
TM 5-3800-205-23-1
ROCKER SWITCHES REPLACEMENT 0049 00
INITIAL SETUP

5-3800-205-10-1 or TM 5-3800-205-10-2)
00)
205-10-1 or TM 5-3800-205-10-2) 3800-205 -10 or TM 5-3800-205-10-2)
NOTE
EMS test, flood lamp, air intake heater, ether start, fuel pump, windshield wiper and windshield washer
rocker switches are replaced the same way. EMS test switch is shown.
REMOVAL
1. Remove six screws (1) and two brackets (2) from switch panel (3).
1 2
390-002
0049 00-1
TM 5-3800-205-23-1
ROCKER SWITCHES REPLACEMENT- CONTINUED 0049 00
REMOVAL - CONTINUED
2. Disconnect harness connector (5) from switch (4). 2 4 5

3. Push switch (4) forward through switch panel (3).
INSTALLATION
1. Position switch (4) on switch panel (3) and connect harness connector (5) to switch.
2. Install switch panel (3) and two brackets (2) with six screws (1).
1 2
390-002
END OF WORK PACKAGE
0049 00-2
TM 5-3800-205-23-1
PARKING LIGHT/BLACKOUT MARKER LIGHT MAINTENANCE 0050 00
Light Assembly: Removal, Installation

Blackout Marker Lens: Removal, Installation
Parking and Turn Signal Bulbs: Removal, Installation
Blackout Marker LED: Removal, Installation
INITIAL SETUP

Unit
Tool kit, general mechanic’s (Item 33, WP 0172 00) Parking brake applied (TM 5-3800-205-10-1 or TM
Gasket Wheels chocked (TM 5-3800-205-10-1 or TM 5-

3800-205-10-2)
Equipment Condition
205-10-1 or TM 5-3800-205-10-2) 3800-205-10-1 or TM 5-3800-205-10-2)
NOTE
Left and right side parking/blackout marker lights are replaced the same way. Left side is shown.
LIGHT ASSEMBLY REMOVAL

1. Disconnect electrical leads (1) from harness connector 1
(2). 2
2. Remove two screws (3), washers (4), and ground lead
(5) from rear of light assembly (6).
3. Remove light assembly (6) from bracket (7). 3
4
5
0050 00-1
TM 5-3800-205-23-1
PARKING LIGHT/BLACKOUT MARKER LIGHT MAINTENANCE - CONTINUED 0050 00
LIGHT ASSEMBLY INSTALLATION

1. Position light assembly (6) on bracket (7). 1
2. Install two screws (3), washers (4), and ground lead 2
(5) at rear of light assembly (6).
3. Connect electrical leads (1) to harness connector (2).
3
4
5
BLACKOUT MARKER LENS REMOVAL

1. Loosen, but do not remove, three screws (8). 8 9
2. Remove two bottom screws (11) and cover (10) from
housing (9).
11 10
0050 00-2
TM 5-3800-205-23-1
BLACKOUT MARKER LENS REMOVAL - CONTINUED
NOTE
Packing should be replaced if there is evidence of moisture inside housing.
3. Remove packing (12) from cover (10). Inspect pack- 10 12

ing for tears or damage. If torn or damaged, replace
packing.
4. Turn cover (10) over and remove two screws (13) and
retainer (14) from cover.
5. Remove marker lens (15) from cover (10).
13
14
15
BLACKOUT MARKER LENS INSTALLATION

1. Position marker lens (15) in cover (10) and install retainer (14) with two screws (13).
2. Install packing (12) in cover (10).
3. Position cover (10) on housing (9).
4. Install two bottom screws (11).
5. Tighten three screws (8).
0050 00-3
TM 5-3800-205-23-1
PARKING AND TURN SIGNAL BULBS REMOVAL

1. Loosen, but do not remove, three screws (8). 8 16 17
2. Remove two middle screws (16).
3. Remove retainer (17) from cover (10).
4. Remove amber lens (18) and gasket (19) from cover
(10). Discard gasket. 18,19
10
NOTE
Top bulb is for parking light. Bottom bulb is for turn signal.
5. Remove bulb (20 or 21). 20 21
0050 00-4
TM 5-3800-205-23-1
PARKING AND TURN SIGNAL BULBS INSTALLATION
NOTE
Top bulb is for parking light. Bottom bulb is for turn signal.
1. Install bulb (20 or 21).

2. Position amber lens (18) and new gasket (19) in cover (10).
3. Install retainer (17) on cover (10).
4. Install two middle screws (16).
BLACKOUT MARKER LED REMOVAL
1. Loosen, but do not remove, three screws (8). 8 9
2. Remove two bottom screws (11).
3. Remove cover (10) from housing (9).
11 10
0050 00-5
TM 5-3800-205-23-1
BLACKOUT MARKER LED REMOVAL - CONTINUED
NOTE
Packing should be replaced if there is evidence of moisture inside housing.
4. Remove packing (12) from cover (10). Inspect pack- 12

10
ing for tears or damage. If torn or damaged, replace
packing.
5. Remove blackout marker LED (22).

22
0050 00-6
TM 5-3800-205-23-1
BLACKOUT MARKER LED INSTALLATION

1. Install blackout marker LED (22). 12
10
2. Install packing (12) in cover (10).
3. Position cover (10) on housing (9). 8 9

4. Install two bottom screws (11).
11 10
END OF WORK PACKAGE
0050 00-7
TM 5-3800-205-23-1
0050 00-8
TM 5-3800-205-23-1
TURN SIGNAL/HAZARD FLASHER SWITCH REPLACEMENT 0051 00
INITIAL SETUP

5-3800-205-10-1 or TM 5-3800-205-10-2)
00)
205-10-1 or TM 5-3800-205-10-2) 3800-205-10-1 or TM 5-3800-205-10-2)
REMOVAL
1. Remove two screws (1) and ground wire (2) from switch (3) on left side of steering column.
0051 00-1
TM 5-3800-205-23-1
TURN SIGNAL/HAZARD FLASHER SWITCH REPLACEMENT - CONTINUED 0051 00
REMOVAL - CONTINUED
2. Disconnect switch leads (4) from harness connector (5).
3. Remove steering column rear upper cover (6).
4. Remove switch (3).
5. Inspect ground wire (2) for damage. If wire is damaged, remove screw (7), washer (8), and ground wire from column
(9).
0051 00-2
TM 5-3800-205-23-1
TURN SIGNAL/HAZARD FLASHER SWITCH REPLACEMENT - CONTINUED 0051 00
REMOVAL - CONTINUED
7,8
9
INSTALLATION
1. If ground wire (2) was removed, install screw (7), washer (8), and ground wire on column (9).
2. Route and connect switch leads (4) to harness connector (5).
3. Install steering column rear upper cover (6).
4. Position switch (3) on column (9).
5. Install switch (3) and ground wire (2) with two screws (1).
END OF WORK PACKAGE
0051 00-3
TM 5-3800-205-23-1
0051 00-4
TM 5-3800-205-24-1
BLACKOUT DRIVE LIGHT MAINTENANCE 0052 00

Bulb Replacement
INITIAL SETUP

5-3800-205-10-1 or TM 5-3800-205-10-2)
00)
205-10-1 or TM 5-3800-205-10-2) 3800-205-10-1 or TM 5-3800-205-10-2)
BULB REPLACEMENT
1. Loosen three captive screws (1) and remove cover (2)
from housing (3).
1
0052 00-1
TM 5-3800-205-24-1
BLACKOUT DRIVE LIGHT MAINTENANCE - CONTINUED 0052 00
BULB REPLACEMENT - CONTINUED

2. Remove bulb (4) from socket (5).
4 5
3. Inspect seal (6) for cracks or tears. Remove and dis- 2 6

card seal from cover (2) if cracked or damaged.
4. If removed, install new seal (6) on cover (2).
0052 00-2
TM 5-3800-205-24-1
BULB REPLACEMENT - CONTINUED

5. Install bulb (4) in socket (5).
6. Position cover (2) on housing (3) and tighten three
captive screws (1).
1

1. Remove four screws (7), washers (8), and access plate 7,8 9 10
(9).
2. Remove two screws (12), four washers (13), and two
nuts (14) from mounting bracket (11).
3. Pull blackout light assembly (10) out through access
plate opening.
11
12
13
14
0052 00-3
TM 5-3800-205-24-1
LIGHT ASSEMBLY REMOVAL - CONTINUED

4. Disconnect electrical lead (15) from light assembly
(10). 15 10
5. Remove nut (16), lockwasher (17), and ground lead
(18) from stud (19).
6. Remove light assembly (10), swivel (20), and spacer
(21) from mounting bracket (11).
21 20 11 16,17,18,19

1. Install light assembly (10), swivel (20), and spacer (21) on mounting bracket (11).
2. Install ground lead (18) on stud (19) with lockwasher (17) and nut (16).
3. Connect electrical lead (15) to light assembly (10).
4. Position light assembly (10), through access plate opening.
5. Install two screws (12), four washers (13), and two nuts (14) on mounting bracket (11).
6. Install access plate (9) with four washers (8) and screws (7).
END OF WORK PACKAGE
0052 00-4
TM 5-3800-205-23-1
DIMMER SWITCH REPLACEMENT 0053 00
INITIAL SETUP

205-10-1 or TM 5-3800-205-10-2)
00) 5-3800-205-10-1 or TM 5-3800-205-10-2)

5-3800-205-10-2)
Lockwasher (5)
3800-205-10-2)
Personnel Required Battery disconnect switch in OFF position (TM 5-
Two 3800-205-10-1 or TM 5-3800-205-10-2)
REMOVAL
1. Pull floor pad (1) back from dimmer switch (2). 1 2
0053 00-1
TM 5-3800-205-23-1
DIMMER SWITCH REPLACEMENT- CONTINUED 0053 00
REMOVAL - CONTINUED
2. Remove three screws (3) and lockwashers (4) from 3,4 2
dimmer switch (2). Discard lockwashers.
3. Remove dimmer switch (2) from cab floor by pushing
dimmer switch down through cab floor.
NOTE
4. Remove two screws (5), lockwashers (6), and wires 5,6,7

(7) from dimmer switch terminals (8). Discard lock-
washers.
5. Remove dimmer switch (2) from machine.
0053 00-2
TM 5-3800-205-23-1
DIMMER SWITCH REPLACEMENT- CONTINUED 0053 00
INSTALLATION
1. Install two wires (7) on dimmer switch terminals (8) with two new lockwashers (6) and screws (5).
2. Position dimmer switch (2) by pushing dimmer switch up through cab floor.
3. With assistance, install three new lockwashers (4) and screws (3) on dimmer switch (2).
4. Position floor pad (1) around dimmer switch (2). 1 2
END OF WORK PACKAGE
0053 00-3
TM 5-3800-205-23-1
0053 00-4
TM 5-3800-205-23-1
HEADLIGHTS REPLACEMENT 0054 00

Headlight: Removal, Installation
INITIAL SETUP

205-10-1 or TM 5-3800-205-10-2)
00) 5-3800-205-10-1 or TM 5-3800-205-10-2)

5-3800-205-10-2)
Gasket
3800-205-10-2)
References Battery disconnect switch in OFF position (TM 5-
WP 0099 00 3800-205-10-1 or TM 5-3800-205-10-2)
NOTE
• This procedure is used for service drive and high beam lights. Right side service drive light is shown.
• Headlight is shown out of position for clarity.
HIGH
BEAM HIGH
BEAM
SERVICE SERVICE
DRIVE DRIVE
0054 00-1
TM 5-3800-205-23-1
HEADLIGHTS REPLACEMENT - CONTINUED 0054 00
LIGHT ASSEMBLY REMOVAL - CONTINUED

1. Remove bolt (1) and washer (2) from mount (3).
1,2
2. Pull light assembly (4) from engine grille (5).
NOTE
3. Remove two screws (6) and electrical leads (7) from light assembly (4).
5 6 7
0054 00-2
TM 5-3800-205-23-1

1. Install two electrical leads (7) on light assembly (4) with two screws (6).
2. Position light assembly (4) in engine grille (5).
3. Install bolt (1) and washer (2) on mount (3).
HEADLIGHT REMOVAL
NOTE
This procedure is used for service drive and high beam lights. Right side service drive light is shown.
1. Remove four screws (8) from body assembly (9).

2. Remove body assembly (9) and gasket (10) from housing (11). Discard gasket.
3. Pull headlight (12) from housing (11).
8 9 10 (HIDDEN)
11 (HIDDEN)
12
0054 00-3
TM 5-3800-205-23-1
HEADLIGHT REMOVAL - CONTINUED
NOTE
4. Disconnect lead (13) from harness connector (14).

5. Disconnect lead (15) from headlight (12).
14 15
13
12
HEADLIGHT INSTALLATION
1. Connect lead (15) to headlight (12).

2. Connect lead (13) to harness connector (14).
NOTE
When installing headlight, ensure word TOP is facing up.
3. Position headlight (12) in housing (11).
NOTE
When installing body assembly, ensure that wide lip of body assembly is at bottom.
4. Install new gasket (10) on body assembly (9) and position body assembly in housing (11).
5. Install four screws (8) in body assembly (9).
0054 00-4
TM 5-3800-205-23-1
HEADLIGHT INSTALLATION - CONTINUED
8 9 10 (HIDDEN)
11 (HIDDEN)
12
END OF WORK PACKAGE
0054 00-5
TM 5-3800-205-23-1
0054 00-6
TM 5-3800-205-23-1
EMS ALARM REPLACEMENT 0055 00
INITIAL SETUP

Unit EMS panel removed (WP 0039 00)

00)
REMOVAL
1. Disconnect electrical leads (1) from harness connector (2).
2. Remove screw (4), washer (5), and alarm (3) from mount boss (6).
6 4,5 3
INSTALLATION
1. Install alarm (3) on mount boss (6) with washer (5) and screw (4).
3. Install EMS panel (WP 0039 00).
END OF WORK PACKAGE
0055 00-1
TM 5-3800-205-23-1
0055 00-2
TM 5-3800-205-23-1
AIR INTAKE HEATER TIMER REPLACEMENT 0056 00
INITIAL SETUP

Unit EMS panel removed (WP 0039 00)

00)
REMOVAL
1. Remove two screws (1) and timer (2).
2. Disconnect leads (4) from harness connector (3).
1 2
4 3
0056 00-1
TM 5-3800-205-23-1
AIR INTAKE HEATER TIMER REPLACEMENT 0056 00
INSTALLATION
1. Install timer (2) with two screws (1).
2. Connect leads (4) to harness connector (3).
3. Install EMS panel (WP 0039 00).
1 2
4 3
END OF WORK PACKAGE
0056 00-2
TM 5-3800-205-24-1
WORK LIGHT MAINTENANCE 0057 00
Lamp: Removal, Installation

Work Light: Removal, Installation
INITIAL SETUP

5-3800-205-10-1 or TM 5-3800-205-10-2)
00)
205-10-1 or TM 5-3800-205-10-2) 3800-205-10-1 or TM 5-3800-205-10-2)
LAMP REMOVAL
1. Remove two clamps (3) from rubber bezel (1). 3 4

2. Remove rubber bezel (1) with lens assembly (2) from 2
work light housing (4) and gently pull outward on 1
bezel to expose rear of lens assembly.
390-1850
0057 00-1
TM 5-3800-205-24-1
WORK LIGHT MAINTENANCE - CONTINUED 0057 00
LAMP REMOVAL - CONTINUED

3. Disconnect white lamp wire (7) from white work light wiring harness wire (8).
4. Pinch together and release two retaining wires (6) and remove lamp (5) from lens assembly (2).
5 6 7 2
390-1851
LAMP INSTALLATION
CAUTION 3 4
Avoid touching glass surface of lamp with 2
1
fingers. Oil from fingers on lamp will
shorten life of lamp.
1. Position lamp (5) on lens assembly (2) and secure with
two retaining wires (6).
2. Connect white lamp wire (7) to white work light wir-
ing harness wire (8).
NOTE
Inspect rubber bezel prior to installation to
ensure it is not damaged. Replace if dam-
aged.
3. Position rubber bezel (1) with lens assembly (2) on
work light (4). Ensure that rubber bezel is fully seated.
4. Install two clamps (3) on rubber bezel (1).
390-1850
0057 00-2
TM 5-3800-205-24-1
WORK LIGHT MAINTENANCE - CONTINUED 0057 00
WORK LIGHT REMOVAL
1. Disconnect tractor wiring harness connector (9) from 4 9

rear of work light housing (4).
2. Remove bolt (14), washer (15), and work light (16)
from work light bracket (13).
10
16
11
12
13
390-1850
14,15
NOTE
Two hydraulic hoses and rubber bushing will also be removed as clamp halves are removed.
3. Remove two bolts (11), washers (12), two clamp halves (10), and work light bracket (13) from tractor.
WORK LIGHT INSTALLATION
NOTE
Two hydraulic hoses and rubber bushing will also be installed as clamp halves are installed.
1. Install work light bracket (13) and two clamp halves (10) on tractor with two washers (12) and bolts (11).
2. Install work light (16) on work light bracket (13) with washer (15) and bolt (14).
3. Connect tractor wiring harness connector (9) to rear of work light housing (4).
END OF WORK PACKAGE
0057 00-3
TM 5-3800-205-24-1
0057 00-4
TM 5-3800-205-23-1
STOP LAMP PRESSURE SWITCH REPLACEMENT 0058 00
INITIAL SETUP

5-3800-205-10-1 or TM 5-3800-205-10-2)
00) 5-3800-205-10-2)
Tape, antiseizing (Item 40, WP 0171 00)
205-10-1 or TM 5-3800-205-10-2) 3800-205-10-2)
REMOVAL
NOTE
Stop lamp pressure switch is connected to service brake control valve below cab floor.
1. Disconnect harness connector (4) from electrical leads (3).

2. Remove pressure switch (2) from control valve (1).
0058 00-1
TM 5-3800-205-23-1
STOP LAMP PRESSURE SWITCH REPLACEMENT - CONTINUED 0058 00
INSTALLATION
1. Apply antiseizing tape to threads of pressure switch (2) and install pressure switch on control valve (1).
END OF WORK PACKAGE
0058 00-2
TM 5-3800-205-23-1
TORQUE CONVERTER TEMPERATURE SWITCH REPLACEMENT 0059 00
INITIAL SETUP

Unit
Tool kit, general mechanic’s (Item 33, WP 0172 00) Parking brake applied (TM 5-3800-205-10-1 or TM
Cap set, protective (Item 5, WP 0171 00) Wheels chocked (TM 5-3800-205-10-1 or TM 5-
Lockwasher (2) Battery disconnect switch in OFF position (TM 5-
3800-205-10-1 or TM 5-3800-205-10-2)
Equipment Condition
205-10-1 or TM 5-3800-205-10-2) or TM 5-3800-205-10-2)
WARNING
Do NOT perform this task when engine is hot. Allow engine to cool down. Failure to follow this warning
REMOVAL
1. Disconnect hose (1) from elbow (2).
1 2
390-1602
0059 00-1
TM 5-3800-205-23-1
TORQUE CONVERTER TEMPERATURE SWITCH REPLACEMENT - CONTINUED 0059 00
REMOVAL - CONTINUED
2. Install protective cap on elbow (2).
NOTE
3. Remove two screws (4), lockwashers (5), and wires (3) from temperature switch (6). Discard lockwashers.
4. Remove temperature switch (6) from torque converter (7).
2 3,4,5
7 6
0059 00-2
TM 5-3800-205-23-1
TORQUE CONVERTER TEMPERATURE SWITCH REPLACEMENT - CONTINUED 0059 00
INSTALLATION
1. Position temperature switch (6) on torque converter (7).
2. Install two screws (4), new lockwashers (5), and wires (3) on temperature switch (6).
3. Remove protective cap from elbow (2)
4. Connect hose (1) to elbow (2).
1 2
390-1602
END OF WORK PACKAGE
0059 00-3
TM 5-3800-205-23-1
This Pages Intentionally Left Blank.
0059 00-4
TM 5-3800-205-23-1
TORQUE CONVERTOR TEMPERATURE SENDER REPLACEMENT 0060 00
INITIAL SETUP

00) 5-3800-205-10-2)
Cap set, protective cap (Item 5, WP 0171 00) 3800-205-10-2)
Starwasher Battery disconnect switch in OFF position (TM 5-
Machine parked on hard, level surface (TM 5-3800- Engine access door opened (TM 5-3800-205 -10-1
205-10-1 or TM 5-3800-205-10-2) or TM 5-3800-205-10-2)
WARNING
Do NOT perform this task when engine is hot. Allow engine to cool down. Failure to follow this warning
0060 00-1
TM 5-3800-205-23-1
TORQUE CONVERTOR TEMPERATURE SENDER REPLACEMENT - CONTINUED 0060 00
REMOVAL
1. Disconnect hose (1) from adapter (2).
2. Install protective cap on adapter (2).
1 2
390-1603
3. Remove nut (3), flatwasher (4), wire terminal (5), starwasher (6), and insulating washer (7) from sender (8). Discard
starwasher.
4. Remove sender (8) from torque converter (9).
3,4,5,6,7 8 9
390-1278
0060 00-2
TM 5-3800-205-23-1
TORQUE CONVERTOR TEMPERATURE SENDER REPLACEMENT - CONTINUED 0060 00
INSTALLATION
1. Install sender (8) on torque converter (9).
2. Install insulating washer (7), new starwasher (6), wire terminal (5), flatwasher (4), and nut (3) on sender (8).
3. Remove protective cap from adapter (2).
4. Connect hose (1) to adapter (2).
END OF WORK PACKAGE
0060 00-3
TM 5-3800-205-23-1
0060 00-4
TM 5-3800-205-23-1
COOLANT TEMPERATURE SENDER REPLACEMENT 0061 00
INITIAL SETUP

Unit WP 0009 00

Tool kit, general mechanic’s (Item 33, WP 0172 Engine access door opened (TM 5-3800-205-10-1
00) or TM 5-3800-205-10-2)
Materials/Parts Coolant drained approximately halfway (WP

0010 00)
Antifreeze (Item 2 or 3, WP 0171 00)
O-ring
Starwasher
REMOVAL
1. Remove nut (1), flatwasher (2), starwasher (3), electrical lead (4), and terminal washer (5) from sender (6). Discard star-
washer.
2. Remove sender (6) from thermostat housing (8).
3. Remove and discard O-ring (7) from sender (6).
1,2,3,4,5
6,7
0061 00-1
TM 5-3800-205-23-1
COOLANT TEMPERATURE SENDER REPLACEMENT- CONTINUED 0061 00
INSTALLATION
1. Coat new O-ring (7) with coolant and install on sender (6).
2. Install sender (6) in thermostat housing (8).
3. Install terminal washer (5), electrical lead (4), new starwasher (3), flatwasher (2), and nut (1) on sender (6).
4. Tighten nut (1).
5. Refill coolant (WP 0009 00 and WP 0010 00).
1,2,3,4,5
6,7
END OF WORK PACKAGE
0061 00-2
TM 5-3800-205-23-1
ENGINE AND TRANSMISSION SPEED SENSORS REPLACEMENT 0062 00
Engine Speed Sensor Replacement

Transmission Speed Sensor Replacement
INITIAL SETUP

Unit Parking brake applied (TM 5-3800-205-10-1 or TM
Tool kit, general mechanic’s (Item 33, WP 0172 Wheels chocked (TM 5-3800-205-10-1 or TM 5-
00) 3800-205-10-2)
Equipment Condition Battery disconnect switch in OFF position (TM 5-

Machine parked on hard, level surface (TM 5-3800- 3800-205-10-1 or TM 5-3800-205-10-2)
205-10-1 or TM 5-3800-205-10-2) Engine access door opened, if replacing engine
Scraper bowl or water tank lowered to ground (TM speed sensor (TM 5-3800-205-10-1 or TM 5-
5-3800-205-10-1 or TM 5-3800-205-10-2) 3800-205-10-2)
ENGINE SPEED SENSOR REPLACEMENT

1. Remove from clip and disconnect sensor connector (1) from harness connector (2).
2. Hold sensor (3) and loosen locknut (4) on sensor.
NOTE
Mark bottom of sensor to aid in installation.
3. Remove sensor (3) from top-left of flywheel housing (5).
1 2
0062 00-1
TM 5-3800-205-23-1
ENGINE SPEED SENSOR REPLACEMENT - CONTINUED
4. Transfer position mark from old sensor (3) to new sensor.
5. Install sensor (3) until position mark on sensor is even with top of flywheel housing (5).
6. Tighten locknut (4) on sensor (3) while holding sensor flat.
7. Connect sensor connector (1) to harness connector (2) and secure connectors in clip.
1 2
TRANSMISSION SPEED SENSOR REPLACEMENT
1. Disconnect sensor connector (10) from harness connector (6).
2. Hold sensor (8) and loosen locknut (7).
NOTE
Mark bottom of sensor to aid in installation.
3. Remove sensor (8) from housing (9).
4. Transfer position mark from old sensor (8) to new sensor.
5. Install sensor (8) until position mark on sensor is even with top of housing (9).
6. Tighten locknut (7) on sensor (8) while holding sensor flat.
7. Connect sensor connector (10) to harness connector (6).
0062 00-2
TM 5-3800-205-23-1
TRANSMISSION SPEED SENSOR REPLACEMENT - CONTINUED
10
9 7
8
END OF WORK PACKAGE
0062 00-3
TM 5-3800-205-23-1
0062 00-4
TM 5-3800-205-23-1
ENGINE TEMPERATURE AND ETHER START AID TEMPERATURE SWITCH REPLACEMENT 0063 00
INITIAL SETUP

Unit Antifreeze (Item 2 or 3, WP 0171 00)
Tools and Special Tools Strap, tiedown (Item 38, WP 0171 00)
Tool kit, general mechanic’s (Item 33, WP 0172 References

00) WP 0009 00
Equipment Condition
Cooling system drained (WP 0010 00)
NOTE
Engine temperature switch and start aid temperature switch are replaced the same way. Engine temperature
switch is shown.
0063 00-1
TM 5-3800-205-23-1
ENGINE TEMPERATURE AND ETHER START AID TEMPERATURE SWITCH

REPLACEMENT - CONTINUED 0063 00
REMOVAL
NOTE
Top switch is for engine temperature. Bottom switch is for ether start aid.
1. Cut tiedown strap from wire bundle. Discard tiedown strap.

2. Remove from clip (4) and disconnect switch connector (5) from harness connector (6).
3. Hold switch (3) and loosen nut (2). Remove switch from thermostat housing (1).
ETHER START AID

TEMPERATURE SWITCH 1
2
6 5
INSTALLATION
1. Position switch (3) in thermostat housing (1) and tighten nut (2).
2. Install new tiestrap around wire bundle.
3. Connect swtich connectors (5) to harness connector (6). Place connectors in clip (4).
4. Fill cooling system (WP 0009 00 and WP 0010 00).
END OF WORK PACKAGE
0063 00-2
TM 5-3800-205-23-1
ENGINE OIL, FUEL LEVEL RELAY, AND EJECTOR DETENT

PRESSURE SWITCHES REPLACEMENT 0064 00
Engine Oil Pressure Switch: Removal, Installation

Ejector Detent Pressure Switch: Removal, Installation
Fuel Level Relay Pressure Switch: Removal, Installation
INITIAL SETUP

Unit Tape, antiseizing (Item 40, WP 0171 00)

Tool kit, general mechanic’s (Item 33, WP 0172 00) Center guard plate removed (WP 0100 00)
ENGINE OIL PRESSURE SWITCH REMOVAL

1. Disconnect harness connector (1) from electrical leads (2).
2. Remove engine oil pressure switch (3) from bracket (4).
1 2
ENGINE OIL PRESSURE SWITCH INSTALLATION

1. Apply antiseizing tape to threads of switch (3) and install switch on bracket (4).
0064 00-1
TM 5-3800-205-23-1
ENGINE OIL, FUEL LEVEL RELAY, AND EJECTOR DETENT PRESSURE

SWITCHES REPLACEMENT - CONTINUED 0064 00
EJECTOR DETENT PRESSURE SWITCH REMOVAL

2. Remove ejector detent pressure switch (7) from bracket (4).
5
6
EJECTOR DETENT PRESSURE SWITCH INSTALLATION

0064 00-2
TM 5-3800-205-23-1
ENGINE OIL, FUEL LEVEL RELAY, AND EJECTOR DETENT PRESSURE

SWITCHES REPLACEMENT - CONTINUED 0064 00
FUEL LEVEL RELAY PRESSURE SWITCH REMOVAL

2. Remove fuel level relay pressure switch (10) from bracket (4).
10
FUEL LEVEL RELAY PRESSURE SWITCH INSTALLATION

END OF WORK PACKAGE
0064 00-3
TM 5-3800-205-23-1
0064 00-4
TM 5-3800-205-23-1
ENGINE FUEL SYSTEM PRESSURE SWITCH REPLACEMENT 0065 00
INITIAL SETUP

Unit Parking brake applied (TM 5-3800-205-10-1 or TM
Tool kit, general mechanic’s (Item 33, WP 0172 Wheels chocked (TM 5-3800-205-10-1 or TM 5-
00) 3800-205-10-2)
Materials/Parts Battery disconnect switch in OFF position (TM 5-
Equipment Condition Engine access door opened (TM 5-3800-205-10-1

Machine parked on hard, level surface (TM 5-3800- or TM 5-3800-205-10-2)
205-10-1 or TM 5-3800-205-10-2) Fuel hose quick disconnects disconnected at draft
Scraper bowl or water tank lowered to ground (TM arm (TM 5-3800-205-10-1 or TM 5-3800-205-
5-3800-205-10-1 or TM 5-3800-205-10-2) 10-2)
WARNING
sparks. Clean up all leaked or spilled fuel. Fuel may ignite, causing damage to machine and injury or
death to personnel.
0065 00-1
TM 5-3800-205-23-1
ENGINE FUEL SYSTEM PRESSURE SWITCH REPLACEMENT - CONTINUED 0065 00
REMOVAL
2. Remove pressure switch (4) from housing (3).
1,2
4
INSTALLATION
1. Install pressure switch (4) on housing (3).
2. Connect leads (1) to harness connector (2).
3. Connect fuel quick disconnects at draft arm (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).
END OF WORK PACKAGE
0065 00-2
TM 5-3800-205-23-1
SERVICE BRAKE AIR SUPPLY BLOCK SOLENOID VALVE REPLACEMENT 0066 00
INITIAL SETUP

Unit Tag, marker (Item 39, WP 0171 00)
Tools and Special Tools Tape, antiseizing (Item 40, WP 0171 00)
Tool kit, general mechanic’s (Item 33, WP 0172 Equipment Condition

00) Rear guard plate removed (WP 0100 00)
Air tanks drained (TM 5-3800-205-10-1 or TM 5-
3800-205-10-2)
WARNING
0066 00-1
TM 5-3800-205-23-1
SERVICE BRAKE AIR SUPPLY BLOCK SOLENOID VALVE REPLACEMENT- CONTINUED 0066 00
REMOVAL
NOTE
Service brake air supply block solenoid is located below cab and above rear crossmember.
1. Disconnect solenoid valve leads (1) from harness connector (2).

2. Disconnect hose (3) from tee (10).
3. Disconnect hose (5) from adapter (6) on valve (7).
4. Disconnect hose (11) from tee (10).
5. Remove two screws (8) and washers (9) from valve clamp (4).
6. Remove valve (7) from crossmember (12).
7. Remove tee (10) and two adapters (6) from valve (7).
8. Inspect two adapters (6) and tee (10) for damage. Replace adapters and tee if damaged. Remove antiseizing tape from
threads of adapters and tee, if adapters and tee are not damaged.
1 2 3 4 5
6
7
6
8,9
10
11
INSTALLATION
1. Apply antiseizing tape to threads of two adapters (6) and tee (10) and install adapters in valve (7).
2. Install tee (10) on lower adapter (6).
3. Install valve (7) on crossmember (12) with valve clamp (4), two screws (8) and washers (9).
4. Connect hose (11) to tee (10).
5. Connect hose (5) to other adapter (6).
6. Connect hose (3) to tee (10).
7. Connect solenoid valve leads (1) to harness connector (2).
8. Install rear guard plate (WP 0100 00).
END OF WORK PACKAGE
0066 00-2
TM 5-3800-205-23-1
BATTERY AND BATTERY CABLES MAINTENANCE 0067 00
Batteries: Removal, Service, Installation

Battery Cables: Removal, Installation
INITIAL SETUP

Unit TM 9-6140-200-14
00) 205-10-1 or TM 5-3800-205-10-2)
0172 00) 5-3800-205-10-1 or TM 5-3800-205-10-2)
Material/Parts Parking brake applied (TM 5-3800-205-10-1 or TM
Rag, wiping (Item 31, WP 0171 00) 5-3800-205-10-2)
Locknut (4) Wheels chocked (TM 5-3800-205-10-1 or TM 5-

3800-205-10-2)
Personnel Required
Two 3800-205-10-1 or TM 5-3800-205-10-2)
WARNING
• To avoid injury, eye protection and acid-resistant gloves must be worn when working around batteries.
Do not smoke, use open flame, make sparks or create other ignition sources around batteries. If a battery
is giving off gases, it can explode and cause injury to personnel. Remove all jewelry such as rings, ID
tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal, a direct short will result in
instant heating, damage to equipment, and injury to personnel.
• Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolyte makes
contact with skin, eyes or clothing, take immediate action to stop the corrosive burning effects. Failure
to follow these procedures may result in death or serious injury to personnel.
a. Eyes. Flush with cold water for no less than 15 minutes and seek medical attention immediately.
b. Skin. Flush with large amounts of cold water until all acid is removed. Seek medical attention as required.
c. Internal. If corrosion or electrolyte is ingested, drink large amounts of water or milk. Follow with milk of magne-
sia, beaten egg or vegetable oil. Seek medical attention immediately.
d. Clothing/Equipment. Wash area with large amounts of cold water. Neutralize acid with baking soda or household
ammonia.
0067 00-1
TM 5-3800-205-23-1
BATTERY AND BATTERY CABLES MAINTENANCE - CONTINUED 0067 00
BATTERIES REMOVAL
1. Open compartment access door (1).
WARNING
• Remove all jewelry such as rings, ID tags, watches, and bracelets when working around batteries. If
jewelry or a tool contacts a battery terminal, a direct short may result, causing instant heating and elec-
tric shock at the point of short circuit. Damage to equipment and injury to personnel could result.
• Cover battery posts with a clean, dry rag to protect against electric shock.
CAUTION
Disconnect battery cables in sequence as described in steps 2 and 3.
2. Pull back protective cover (2). Loosen nut (3) and remove cable clamp (4) from terminal (5).
3. Repeat step 2 for terminals (7, 8, and 6).
2
3,4,5
1
4. Remove four locknuts (9), washers (10), and battery hold-down (11) from two batteries (12). Discard locknuts.
NOTE
Mark bottom of rods to aid in installation.
5. Loosen nuts (13), washers (14), and remove both front rods (15) from battery compartment. Inspect front and rear rods
for damage. Replace any rods that are damaged.
0067 00-2
TM 5-3800-205-23-1
BATTERIES REMOVAL - CONTINUED
10 11
9
12
390-127
14 12,13
15
390-127
14 13
0067 00-3
TM 5-3800-205-23-1
BATTERIES REMOVAL - CONTINUED
WARNING
NOTE
• Each battery weighs 65 lb (30 kg).
• Note position of batteries for installation.
6. With assistance, remove two batteries (12) from battery compartment.
NEGATIVE (-) 12
12 POSITIVE (+)
NEGATIVE (-)
POSITIVE (+)
SERVICE
Service batteries in accordance with TM 9-6140-200-14.
0067 00-4
TM 5-3800-205-23-1
BATTERIES INSTALLATION
WARNING
NOTE
Each battery weighs 65 lb (30 kg).
1. With assistance, position two batteries (12) in battery compartment.

2. Install rods (15) in battery compartment and secure with nuts (13) and washers (14).
3. Position battery hold-down (11) on top of batteries (12) and secure with four new locknuts (9) and washers (10).
10 11
9
12
390-127
14 12,13
15
390-127
14 13
0067 00-5
TM 5-3800-205-23-1
BATTERIES INSTALLATION - CONTINUED
WARNING
• Remove all jewelry such as rings, ID tags, watches, and bracelets when working around batteries. If
jewelry or a tool contacts a battery terminal, a direct short may result, causing instant heating and elec-
tric shock at the point of short circuit. Damage to equipment and injury to personnel could result.
• Cover battery posts with a clean, dry rag to protect against electric shock.
CAUTION
Connect battery cables in sequence as described in steps 4 through 6.
4. Install cable clamp (4) on terminal (6) and tighten nut (3).
5. Install protective cover (2) over cable clamp (4).
6. Repeat steps 4 and 5 for terminals (8, 7, and 5).
7. Close compartment access door (1).
5
1
3,4,6
390-996
0067 00-6
TM 5-3800-205-23-1
BATTERY CABLES REMOVAL
WARNING
Remove all jewelry such as rings, ID tags, watches, and bracelets when working around batteries. If jewelry
or a tool contacts a battery terminal, a direct short may result, causing instant heating and electric shock at
the point of short circuit. Damage to equipment and injury to personnel could result.
NOTE
Cover battery posts with a clean, dry rag.
1. Disconnect batteries (12) in accordance with steps 2 and 3 of Batteries Removal.

2. Loosen, but do not remove, screw (16) enough to pull cables (17 and 18) from cable clamp (19).
NEGATIVE POSITIVE
CABLE 16 CABLE
17
12
18
390-127
14 12,13
19
390-127
0067 00-7
TM 5-3800-205-23-1
BATTERY CABLES REMOVAL - CONTINUED
3. Loosen, but do not remove, screw (20) enough to pull positive cable (17) from cable clamp (21).
20
21
17
4. Pull back rubber boot (22) and remove nut (23), washer (24), and cable (17) from terminal (25) on junction block (26).
5. Do not remove other washer (24) from terminal (25).
22 17,23,24,25
26
0067 00-8
TM 5-3800-205-23-1
BATTERY CABLES REMOVAL - CONTINUED

6. Pull back rubber boot (27) and remove nut (28), washer (29), and negative cable (18) from terminal (30) on battery dis-
connect switch (31).
7. Loosen, but do not remove, screw (32) enough to pull cable (18) from clamp (33).
27 18,28,29,30
31
18
32
33
8. Loosen, but do not remove, screw (34) enough to pull cable (18) from clamp (35).
18
34
35
19
390-1264
0067 00-9
TM 5-3800-205-23-1
BATTERY CABLES INSTALLATION

1. Position cable (18) in clamp (35).
18
34
35
19
390-1264
2. Position cable (18) in clamp (33).

3. Install cable (18), washer (29), and nut (28) on terminal (30) of battery disconnect switch (31). Tighten nut.
4. Install boot (27) on terminal (30).
5. Tighten screws (32 and 34).
27 18,28,29,30
31
18
32
33
0067 00-10
TM 5-3800-205-23-1
BATTERY CABLES INSTALLATION - CONTINUED

6. Install cable (17), washer (24), and nut (23) on terminal (25) on junction block (26). Tighten nut.
7. Install boot (22) on terminal (25).
22 17,23,24,25
26
8. Position cable (17) in clamp (21) and tighten screw (20).

20
21
17
0067 00-11
TM 5-3800-205-23-1
BATTERY CABLES INSTALLATION - CONTINUED

9. Position cables (17 and 18) in clamp (19). Tighten screw (16).
10. Connect batteries (12) in accordance with steps 4 through 6 of Batteries Installation.
NEGATIVE POSITIVE
CABLE 16
12 17 CABLE
18
390-127
14 12,13
19
390-127
END OF WORK PACKAGE
0067 00-12
TM 5-3800-205-23-1
SLAVE START RECEPTACLE AND CABLES REPLACEMENT 0068 00
INITIAL SETUP
Unit Two
Equipment Condition
Machine parked on hard, level ground (TM 5-3800-
Tool kit, general mechanic’s (Item 33, WP 0172 205-10-1 or TM 5-3800-205-10-2)
00) Scraper bowl or water tank lowered to ground (TM
5-3800-205-10-1 or TM 5-3800-205-10-2)
Materials/Parts
Tag, marker (Item 39, WP 0171 00) 5-3800-205-10-2)
Locknut (4) 3800-205-10-2)
Lockwasher (2) Battery cables disconnected (WP 0067 00)
REMOVAL
1. Remove protective cover (1) from slave start receptacle (2).
2. Open engine access door to access back of slave start receptacle (2).
1
0068 00-1
TM 5-3800-205-23-1
SLAVE START RECEPTACLE AND CABLES REPLACEMENT - CONTINUED 0068 00
REMOVAL - CONTINUED
3. Remove protective boots (3) from terminals (7 and 8).
NOTE
Tag all cables to aid in installation.
4. Remove screw (4), lockwasher (5), and negative cable (6) from terminal (7). Discard lockwasher.
5. Remove other screw (4), lockwasher (5) and positive cable (9) from terminal (8). Discard lockwasher.
3
4,5,6
4,5,9 8 7
6. Remove four screws (10), washers (11), locknuts (12), and cover strap (13) from slave start receptacle (2). Discard lock-
nuts.
7. With assistance, pull slave start receptacle (2) from bulkhead (14).
2
10,11,12
14
13
0068 00-2
TM 5-3800-205-23-1
REMOVAL - CONTINUED
8. Loosen but do not remove screw (15) and washer (16) on clamp (17).
9. Pull cables (6 and 9) from clamp (17).
15,16,17
390-2124
9 6
10. Remove nut (18), washer (19), and cable (6) from starter terminal (20).
11. Loosen, but do not remove, screw (21) and washer (22) on clamp (23) and pull cable (9) from clamp.
12. Remove nut (24), washer (25), and cable (9) from starter terminal (26).
6,18,19,20
9,24,25,26
23 21,22
0068 00-3
TM 5-3800-205-23-1
INSTALLATION
1. Install nut (24), washer (25), and cable (9) on starter terminal (26). Tighten nut.
2. Position cable (9) in clamp (23) and tighten screw (21) and washer (22).
3. Install nut (18), washer (19), and cable (6) on starter terminal (20). Tighten nut.
6,18,19,20
9,24,25,26
23 21,22
4. Position cables (6 and 9) in clamp (17).

5. Tighten screw (15) and washer (16) on clamp (17).
15,16,17
390-2124
9 6
0068 00-4
TM 5-3800-205-23-1
6. Position slave start receptacle (2) on bulkhead (14).
7. Install four screws (10), washers (11), new locknuts (12), and cover strap (13) to secure slave start receptacle (2).
2
10,11,12
14
13
8. Install screw (4), new lockwasher (5), and positive cable (9) on terminal (8).
9. Install other screw (4), new lockwasher (5), and negative cable (6) on terminal (7).
10. Install protective boots (3) on terminals (7 and 8).
4,5,6
4,5,9 8 7
0068 00-5
TM 5-3800-205-23-1
11. Install protective cover (1) on slave start receptacle (2).

13. Close engine access door.
END OF WORK PACKAGE
0068 00-6
TM 5-3800-205-23-1
TRANSMISSION SHIFT CONTROL CABLE REPLACEMENT 0069 00
INITIAL SETUP

Unit Washer, seal
00) 205-10-1 or TM 5-3800-205-10-2)
5-3800-205-10-1 or TM 5-3800-205-10-2)
Grease, GAA (Item 16, WP 0171 00)
Sealant, silicone (Item 35, WP 0171 00)
5-3800-205-10-2)
Strap, tiedown (Item 38, WP 0171 00)
Gasket 3800-205-10-2)
Pin, cotter Battery disconnect switch in OFF position (TM 5-
Pin, spring (3) 3800-205-10-1 or TM 5-3800-205-10-2)
REMOVAL
1. Disconnect wiring harness connector (2) from work 1 2
light (1).
0069 00-1
TM 5-3800-205-23-1
TRANSMISSION SHIFT CONTROL CABLE REPLACEMENT - CONTINUED 0069 00
REMOVAL - CONTINUED
2. Remove two screws (4), washers (5), and work light bracket (3), with work light (1), from cover (6).
NOTE
Three cable clamps, washers, and one cable connector holder are also removed as transmission cover is
removed. Note position of clamps, washers, and cable connector holder to aid in installation.
3. Remove 10 screws (9), four washers (10), cover (6),
and gasket (7) from linkage housing (8). Discard gas-
ket.
3
4,5
9,10
8 6,7
4. Remove screw (21), washer (22), and bearing (18) from cam (20).
NOTE
Note position of bearing and nut on shift control cable to aid in installation.
5. Remove grease fitting (19), bearing (18), and nut (17) from shift control cable (16).
NOTE
Note position of two nuts, washers, and seal washer on shift control cable to aid in installation.
6. Remove nut (11), washer (12), and seal washer (13) from shift control cable (16). Discard seal washer.
7. Pull shift control cable (16) out through hole in linkage housing (8).
0069 00-2
TM 5-3800-205-23-1
REMOVAL - CONTINUED
8. Remove washer (14) and nut (15) from shift control 11,12,13
cable (16). 14,15
8
16
17
21,22 18
19
20
9. Remove two screws (24), washers (25), and clamps

(26) holding shift control cable (16) to machine.
10. Remove and discard tiedown straps to separate wiring
harness (23) from shift control cable (16).
16
23
24,25
26
0069 00-3
TM 5-3800-205-23-1
REMOVAL - CONTINUED
11. Remove and discard two tiedown straps and remove
insulating sleeve (28) from shift control cable (16). 27
12. Remove sealant from around shift control cable (16) at
rear of cab (27).
28
16
13. Remove spring pin (38) from neutral lock lever (39). Discard spring pin.
16. Remove knob (29) from transmission shift lever (40).
30 31 32
29
33
40
39
34
38
35
37 36
0069 00-4
TM 5-3800-205-23-1
REMOVAL - CONTINUED
17. Inspect seal inside nuts (35 and 36) for cracks or dam- 35,36 SEAL
age. Discard nuts if seal is damaged.
41,42
43
390-1776
0069 00-5
TM 5-3800-205-23-1
REMOVAL - CONTINUED
19. Remove cotter pin (44), pin (45), and shift control cable (16) from transmission shift lever (40). Discard cotter pin.
NOTE
Note position of two nuts on shift control cable to aid in installation.
20. Loosen two nuts (46 and 47). Lift shift control cable (16) free from bracket (48) and pull shift control cable out from
hole in cab (27).
45 16 46
27
44
47
40 48
INSTALLATION
1. Position shift control cable (16) in through hole of cab (27) and position shift control cable to bracket (48). Tighten nuts
(46 and 47).
2. Install end of shift control cable (16) on transmission shift lever (40) with pin (45) and new cotter pin (44).
3. Install panel (43) on cab with four washers (42) and screws (41).
41,42
43
390-1776
0069 00-6
TM 5-3800-205-23-1
4. Install knob (29) on transmission shift lever (40)
5. Install nut (35) on valve (34). Install emergency brake handle (33) on valve with new spring pin (32).
6. Install nut (36) on valve (37). Install parking brake handle (31) on valve with new spring pin (30).
30 31 32
29
33
40
39
34
38
37 36 35
8. Apply sealant around shift control cable (16) at rear of cab (27).
9. Install insulating sleeve (28) to shift control cable (16)
with two new tiedown straps. 27
28
16
0069 00-7
TM 5-3800-205-23-1
10. Install new tiedown straps to secure wiring harness

(23) to shift control cable (16).
11. Install shift control cable (16) to machine with two
clamps (26), washers (25), and screws (24).
16
23
24,25
26
12. Position washer (14) and nut (15) to shift control cable 11,12,13
(16). 14,15
8
13. Push end of shift control cable (16) in through hole in
linkage housing (8).
14. Inside linkage housing (8), install new seal washer
(13), washer (12), and nut (11). 16
15. Tighten nuts (11 and 15) against linkage housing (8).
16. Install nut (17) and bearing (18) to end of shift control
cable (16). Install grease fitting (19) to bearing.
17. Connect bearing (18) to cam (20) with washer (22) 17
and screw (21). Lubricate bearing with grease.
18. In cab, move transmission shift lever (TM 5-3800- 21,22 18
205-10-1 or TM 5-3800-205-10-2) to ensure full range
of movement. Adjust shift control cable (16), as 19
required, by positioning nuts (11 and 15). Tighten
nuts.
20
0069 00-8
TM 5-3800-205-23-1
NOTE
Three cable clamps, washers, and one cable connector holder are also installed as cover is installed.
19. Install new gasket (7) and cover (6) on linkage hous- 1 2
ing (8) with four washers (10) and 10 screws (9).
20. Install work light bracket (3), with work light (1), on
cover (6) with two washers (5) and screws (4).
21. Connect wiring harness connector (2) to work light
3
(1).
4,5
9,10
8 6,7
END OF WORK PACKAGE
0069 00-9
TM 5-3800-205-23-1
0069 00-10
TM 5-3800-205-23-1
TRANSMISSION SHIFT CONTROL CAM AND LINKAGE REPLACEMENT 0070 00
Removal, Installation, Adjustment
INITIAL SETUP

Unit
Locknut (3)
Tool kit, general mechanic’s (Item 33, WP 0172 O-ring (4)
00) Ring, retaining (2)
Materials/Parts
Equipment Condition
Oil, lubricating (Item 24, 27, 28 or 29, WP 0171
00) Transmission shift control cable disconnected from
Gasket transmission (WP 0069 00)
REMOVAL
NOTE
Note position of flat spring assembly and detent notches in cam to aid in installation.
1. Remove locknut (4), bolt (12), washer (13), and flat 2,3 4
spring assembly (7) from block (5). Discard locknut.
1
2. Remove two bolts (2), washers (3), block (5), and
spacer block (6) from linkage housing (1).
NOTE
5
Bolt and washer are located underneath 12,13 6

linkage housing.
3. Remove bolt (8), washer (9), and cam pivot pin (10).
7
NOTE
11
Note position of two levers and channels
of cam as cam is removed.
4. Remove cam (11) from linkage housing (1).
8,9,10
0070 00-1
TM 5-3800-205-23-1
TRANSMISSION SHIFT CONTROL CAM AND LINKAGE REPLACEMENT - CONTINUED 0070 00
REMOVAL - CONTINUED
NOTE
Bolts and washers are located underneath linkage housing.
5. Remove two bolts (14), washers (15), lever pivot pins 14,15,16 17
(16), and two levers (17 and 19) from linkage housing
(1) and two rods (18).
1
18
19
6. Remove retaining ring (21) and cam follower (20) 17,19 20

from each of two levers (17 and 19). Discard retaining
rings.
21
0070 00-2
TM 5-3800-205-23-1
REMOVAL - CONTINUED
7. Remove two bolts (25), washers (26), and lube fitting 22 25,26
23,24 27
bracket (27) from cover (23). Set bracket aside.
NOTE
Three cable clamps and wiring harness are
also removed as cover is removed.
8. Remove 16 additional bolts (22), cover (23), and gas-
ket (24) from top of control valve housing. Discard
gasket.
NOTE
• Perform steps 9 through 12 to remove each of two rods.
• Note position of rod and locknut at each spool to aid in installation.
9. While holding spool (29) from rotating, loosen lock- 1 18 28 29
nut (28).
10. Rotate spool (29) to separate spool from rod (18).
11. Remove rod (18) from linkage housing (1).
12. Remove locknut (28) from rod (18). Discard locknut.
0070 00-3
TM 5-3800-205-23-1
REMOVAL - CONTINUED
NOTE
Two bolts are located underneath linkage housing.
13. Remove four bolts (30) and linkage housing (1) from
control valve housing.
30
14. Remove two O-rings (31) and two O-rings (32) from 1 31
linkage housing (1). Discard O-rings.
32
0070 00-4
TM 5-3800-205-23-1
INSTALLATION
1. Coat with oil and install two new O-rings (32) and two new O-rings (31) to linkage housing (1).
NOTE
Two bolts are installed from under linkage housing.
2. Install linkage housing (1) to control valve housing with four bolts (30).
NOTE
Perform steps 3 through 6 to install each of two rods.
3. Install new locknut (28) to rod (18). 1 18 28 29
4. Position rod (18) through linkage housing (1).
NOTE
Install rod and locknut in same position as
noted during removal.
5. Rotate spool (29) to install spool to rod (18).
6. While holding spool (29) from rotating, tighten lock-
nut (28).
NOTE
Wiring harness and three cable clamps are also installed as cover is installed.
7. Install new gasket (24) and cover (23) to top of control 22 25,26
23,24 27
valve housing with 16 bolts (22).
8. Install lube fitting bracket (27) to cover (23) with two
additional washers (26) and bolts (25).
0070 00-5
TM 5-3800-205-23-1
9. Install cam follower (20) to each of two levers (17 and 17,19 20
19) with new retaining ring (21).
21
10. Install two levers (17 and 19) to two rods (18) and 14,15,16 17
linkage housing (1) with two lever pivot pins (16),
washers (15), and bolts (14).
1
18
19
0070 00-6
TM 5-3800-205-23-1
11. Position cam (11) to linkage housing (1). 2,3 4
12. Install cam (11) to linkage housing (1) with cam pivot 1
pin (10), washer (9), and bolt (8).
13. Install spacer block (6) and block (5) to linkage hous-
ing (1) with two washers (3) and bolts (2). 5
NOTE 12,13 6
Install flat spring assembly and detent
notches in cam in same position as noted
during removal. 7
14. Install flat spring assembly (7) to block (5) with

11
washer (13), bolt (12), and new locknut (4).
15. Connect transmission shift control cable to transmis-
sion (WP 0069 00).
8,9,10
ADJUSTMENT
1. Remove cover from linkage housing (WP 0069 00).
2. Remove cover from control valve housing (Refer to Removal steps 7 and 8).
3. In cab, place transmission shift lever in position 4 (TM
5-3800-205-10-1 or TM 5-3800-205-10-2).
NOTE
Cam is marked with a number “4”. 7
11
4. Confirm that flat spring assembly (7) fully engages
detent “4” of cam (11). If not, adjust length of trans-
mission shift control cable (33) (WP 0069 00).
33
0070 00-7
TM 5-3800-205-23-1
ADJUSTMENT - CONTINUED
5. Ends of two spools (29) should now be flush with
front surface (34) of transmission control valve. If not,
adjust position of rod in spool (Refer to Installation
steps 5 and 6). 34
29
6. Install cover to control valve housing. (Refer to Installation steps 7 and 8).
7. Install cover to linkage housing (WP 0069 00).
END OF WORK PACKAGE
0070 00-8
TM 5-3800-205-23-1
TRANSMISSION SHIFT LEVER AND LOCK REPLACEMENT 0071 00
INITIAL SETUP

205-10-1 or TM 5-3800-205-10-2)
00)
Bushing (3)
3800-205-10-2)
Pin, cotter
Pin, spring (3) 3800-205-10-1 or TM 5-3800-205-10-2)
REMOVAL
1. Remove spring pin (10) from neutral lock lever (11). Discard spring pin.
4. Remove knob (1) from transmission shift lever (12).
2 3 4
1
5
12
11
6
10
7
9 8
0071 00-1
TM 5-3800-205-23-1
TRANSMISSION SHIFT LEVER AND LOCK REPLACEMENT - CONTINUED 0071 00
REMOVAL - CONTINUED
5. Inspect seal inside nuts (7 and 8) for cracks or damage. Discard nuts if seal is damaged.
7,8 SEAL
11,12
13
390-1776
0071 00-2
TM 5-3800-205-23-1
REMOVAL - CONTINUED
7. Remove cotter pin (14), pin (15), and shift control cable (16) from shift lever (12). Discard cotter pin.
8. Remove two screws (19) and washers (20) from carrier (18).
9. Loosen nut (17) as required and remove shift lever (12) assembly from cab.
15 16 17
14
390-1399
12 18
19,20
10. Remove spring (28) from shift lever (12) and block
(26). 12
11. Remove setscrew (23), shaft (27), and shift lever (12)
from block (26).
12. Remove two bushings (21) from shift lever (12). Dis- 28 21
card bushings.
13. Remove setscrew (25), shaft (24), and block (26) from
carrier (18).
21
14. Remove bushing (22) from block (26). Discard bush-
22
ing.
27 23
26 24
25
18
0071 00-3
TM 5-3800-205-23-1
REMOVAL - CONTINUED
15. Remove two screws (30), washers (31), plate (29), lock (35), and spring (33) from bracket (32).
16. Remove two screws (34) from lock (35).
INSTALLATION
1. Install two screws (34) on lock (35).
2. Install spring (33), lock (35), and plate (29) on bracket (32) with two washers (31) and screws (30).
3. Install new bushing (22) on block (26).
4. Install block (26) on carrier (18) with shaft (24).
5. Install setscrew (25) on carrier (18).
6. Install two new bushings (21) on shift lever (12).
7. Install shaft (27) and shift lever (12) on block (26) with setscrew (23).
8. Install spring (28) on block (26) and shift lever (12).
30
31
29
12
28 21
35
34
21
22
33
23
27
26 24
25
18
32
0071 00-4
TM 5-3800-205-23-1
9. Install shift lever (12) assembly on cab with two washers (20) and screws (19).
10. Install shift control cable (16) on shift lever (12) with pin (15) and new cotter pin (14).
11. Tighten nut (17) as required.
15 16 17
14
390-1399
12 18
19,20
11,12
13
390-1776
0071 00-5
TM 5-3800-205-23-1
13. Install knob (1) on transmission shift lever (12)
14. Install nut (7) on valve (6). Install emergency brake handle (5) on valve with new spring pin (4).
15. Install nut (8) on valve (9). Install parking brake handle (3) on valve with new spring pin (2).
2 3 4
1
5
12
11
6
10
7
9 8
END OF WORK PACKAGE
0071 00-6
TM 5-3800-205-23-1
TRANSMISSION OIL FILTER AND OIL FILTER BASE REPLACEMENT 0072 00
Oil Filter: Removal, Installation

Oil Filter Base: Removal, Installation
INITIAL SETUP

Unit WP 0009 00
Tools and Special Tools WP 0010 00
00) Equipment Condition
Shop equipment, common no. 1 (Item 24, WP Machine parked on hard, level surface (TM 5-3800-
0172 00) 205-10-1 or TM 5-3800-205-10-2)
Cap set, protective (Item 5, WP 0171 00) 5-3800-205-10-1 or TM 5-3800-205-10-2)
Oil, lubricating (Item 24, 27, 28 or 29, WP 0171 Parking brake applied (TM 5-3800-205-10-1 or TM
00) 5-3800-205-10-2)
Filter element, fluid 3800-205-10-2)
O-ring (3) Battery disconnect switch in OFF position (TM 5-
Seal 3800-205-10-1 or TM 5-3800-205-10-2)
WARNING
• At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any
hydraulic lines. Failure to do so could result in injury.
• Transmission fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may
NOTE
• Cap all lines and openings to prevent fluid loss and contamination of transmission oil.
0072 00-1
TM 5-3800-205-23-1
TRANSMISSION OIL FILTER AND OIL FILTER BASE REPLACEMENT - CONTINUED 0072 00
OIL FILTER REMOVAL

1. Clean filter base (2) and oil filter body (1). 2 SEAL (HIDDEN)
2. Remove drain plug (3) and O-ring and drain oil from
oil filter body (1) into a suitable container. Discard O-
ring. 1
3. Remove oil filter body (1) from filter base (2).
4. Remove and discard filter element (4) from oil filter
body (1).
5. Remove seal from filter base (2) and discard.
4
(HIDDEN)
390-1858
3
OIL FILTER INSTALLATION

1. Clean inside of oil filter body (1) with a clean rag.
2. Insert new filter element (4) inside oil filter body (1).
3. Coat with oil and install new seal in filter base (2).
4. Install oil filter body (1) to filter base (2).
5. Clean drain plug (3). Coat with oil and install new O-ring and drain plug to oil filter body (1).
0072 00-2
TM 5-3800-205-23-1
OIL FILTER BASE REMOVAL

1. Remove transmission oil filter and body from filter 5,6,7 2
base (2) (Refer to Oil Filter Removal).
2. Remove two hoses with flange fittings from filter base
(2).
3. Remove three nuts (5), washers (6), bolts (7), and fil-
ter base (2) from bracket (8).
8
9
4. Remove plug (9) and O-ring (10) from filter base (2). 9,10 2
Discard O-ring.
5. Remove plug (11), O-ring (12), spool valve (13), and 2

spring (14) from filter base (2). Discard O-ring.
14 13 12 11
0072 00-3
TM 5-3800-205-23-1
OIL FILTER BASE REMOVAL - CONTINUED

6. If not already removed, remove seal (15) from filter 15 2
base (2). Discard seal.
WARNING
Sudden release of spring force can cause injury. Wear eye protection and use caution when removing spring,
to prevent injury.
7. Remove retaining ring (16) from shaft (17). 1 16 17 18
8. Remove retainer (18) and spring (19) from oil filter
body (1).
19 (HIDDEN)
0072 00-4
TM 5-3800-205-23-1
OIL FILTER BASE INSTALLATION
WARNING
Sudden release of spring force can cause injury. Wear eye protection and use caution when installing spring,
to prevent injury.
1. Position spring (19) and retainer (18) on oil filter body (1) and install retaining ring (16) on shaft (17).
2. Coat with oil and install new seal (15) on filter base (2).
3. Coat with oil and install spring (14), spool valve (13), 2
new O-ring (12), and plug (11) to filter base (2).
14 13 12 11
4. Coat with oil and install new O-ring (10) and plug (9) 9,10 2
to filter base (2).
0072 00-5
TM 5-3800-205-23-1
OIL FILTER BASE INSTALLATION - CONTINUED

5. Install filter base (2) on bracket (8) with three bolts 5,6,7 2
(7), washers (6), and nuts (5).
8
9
6. Install two hoses with flange fittings to filter base (2).

7. Install transmission oil filter and body to filter base (Refer to Oil Filter Installation).
8. Check transmission oil level and add as needed (WP 0009 00 and WP 0010 00).
END OF WORK PACKAGE
0072 00-6
TM 5-3800-205-23-1
TRANSMISSION OIL SAMPLING VALVE REPLACEMENT 0073 00
Replacement
INITIAL SETUP

205-10-1 or TM 5-3800-205-10-2)
Scaper bowl or water tank lowered to ground (TM
5-3800-205-10-1 or TM 5-3800-205-10-2)
00)
Oil, lubricating (Item 24, 27, 28 or 29, WP 0171 Wheels chocked (TM 5-3800-205-10-1 or TM 5-
00) 3800-205-10-2)
O-ring 3800-205-10-1 or TM 5-3800-205-10-2)
REPLACEMENT
1. Remove oil sampling valve (1) and O-ring (2) from elbow (3). Discard O-ring.
2. Lightly coat new O-ring (2) with clean oil.
3. Install new O-ring (2) and oil sampling valve (1) to elbow (3).
1,2
390-1017
3
0073 00-1
TM 5-3800-205-23-1
TRANSMISSION OIL SAMPLING VALVE REPLACEMENT - CONTINUED 0073 00
REPLACEMENT - CONTINUED
WARNING
4. Start engine (TM 5-3800-205-10-1 or TM 5-3800-205-10-2). Move transmission shift lever through all positions. Check
for leaks.
END OF WORK PACKAGE
0073 00-2
TM 5-3800-205-23-1
TRANSMISSION OIL COOLER REPLACEMENT 0074 00
INITIAL SETUP

Unit
Two
Tool kit, general mechanic’s (Item 33, WP 0172 References
00)
TM 5-3800-205-10-1
0172 00) TM 5-3800-205-10-2
Materials/Parts WP 0009 00
WP 0010 00
Oil, lubricating (Item 24, 27, 28 or 29, WP 0171
00) Equipment Condition
Engine grille removed (WP 0099 00)
Seal, O-ring (2) Hydraulic oil cooler removed (WP 0026 00)
WARNING
• At operating temperature, transmission oil is hot. Allow oil to cool before disconnecting any transmis-
sion lines. Failure to do so could result in injury.
• Transmission oil is very slippery. Immediately wipe up any spills. Failure to follow this warning may
CAUTION
Cap hoses to prevent fluid loss and contamination of system.
NOTE
• Tag all hoses to aid in installation.
0074 00-1
TM 5-3800-205-23-1
TRANSMISSION OIL COOLER REPLACEMENT - CONTINUED 0074 00
REMOVAL
1. Disconnect two hydraulic hose assemblies (1) from transmission oil cooler (5). Remove and discard O-rings from
hydraulic hose assemblies.
2. Remove six nuts (2), 12 washers (3), six bolts (4) and transmission oil cooler (5) from radiator.
3. Remove elbows from transmission oil cooler (5).
1 2,3,4 5
390-1422
1
INSTALLATION
1. Install elbows on transmission oil cooler (5).

2. Install transmission oil cooler (5) on radiator with six bolts (4), 12 washers (3), and six nuts (2).
3. Coat with oil and install new O-rings in two hydraulic hose assemblies (1).
4. Connect two hydraulic hose assemblies (1) to elbows on transmission oil cooler (5).
5. Install hydraulic oil cooler (WP 0026 00).
6. Check transmission oil level and add as needed (WP 0009 00 and WP 0010 00).
WARNING
7. Operate transmission (TM 5-3800-205-10-1 or TM 5-3800-205-10-2) and check for leaks.

8. Install engine grille (WP 0099 00).
END OF WORK PACKAGE
0074 00-2
TM 5-3800-205-23-1
TRANSMISSION OIL SUCTION SCREEN AND TUBE ASSEMBLY

(MAGNETIC SCREEN) REPLACEMENT 0075 00
Removal, Cleaning and Inspection, Installation
INITIAL SETUP

Unit Oil, lubricating (Item 24, 27, 28 or 29, WP 0171
00)
00) O-ring seal
Shop equipment, common no. 1 (Item 24, WP References
0172 00)
WP 0009 00
Materials/Parts
Equipment Condition
Cleaning compound, solvent (Item 6, WP 0171
00) Transmission oil drained (WP 0010 00)
WARNING
Transmission oil is very slippery. Immediately wipe up any spills. Failure to follow this warning may result
in injury to personnel.
NOTE
• Care must be taken to ensure that fluids are contained during performance and repair of machine. Col-
lect all fluids with a suitable container before removing transmission cover plate.
REMOVAL
1. Remove four bolts (1) and cover assembly (2). 1
0075 00-1
TM 5-3800-205-23-1

(MAGNETIC SCREEN) REPLACEMENT - CONTINUED 0075 00
REMOVAL - CONTINUED
2. Remove and discard O-ring (7) from cover assem- 3
bly (2).
3. Remove transmission oil suction screen (3) and tube
assembly (magnetic screen) (4) from transmission
case. 4
4. Remove two screws (5) and spring washer (6) from

cover assembly (2).
2 7
6
CLEANING AND INSPECTION
WARNING
Solvent cleaning compound MIL-PRF-680 Type III is an environmentally compliant and low toxic
material. However, it may be irritating to the eyes and skin. The use of protective gloves and goggles is
suggested. Use in well-ventilated areas. Keep away from open flames and other sources of ignition.
CAUTION
Do NOT rap magnets on hard objects or damage to magnets may result.
1. Clean all removed components in cleaning compound and dry thoroughly.

2. Separate magnets from screen and clean. Use a clean rag or a stiff bristle brush.
3. If magnets are damaged, replace tube assembly (magnetic screen).
4. Replace any other damaged or worn component.
0075 00-2
TM 5-3800-205-23-1

(MAGNETIC SCREEN) REPLACEMENT - CONTINUED 0075 00
INSTALLATION
1. Install spring washer (6) to cover assembly (2) with two screws (5).
2. Install transmission tube assembly (magnetic screen) (4) and oil filter screen (3) in transmission case.
3. Coat with oil and install new O-ring (7) on cover assembly (2).
4. Install cover assembly (2) to transmission case with 1
four bolts (1).
5. Fill transmission to proper level (WP 0009 00 and
WP 0010 00). 2
END OF WORK PACKAGE
0075 00-3
TM 5-3800-205-23-1
0075 00-4
TM 5-3800-205-23-1
LOWER PROP SHAFT MAINTENANCE 0076 00
Removal, Disassembly, Assembly, Installation
INITIAL SETUP

WP 0009 00
Unit
WP 0010 00
205-10-1 or TM 5-3800-205-10-2)
00)
Shop equipment, common no. 1 (Item 24, WP 5-3800-205-10-1 or TM 5-3800-205-10-2)
0172 00) Parking brake applied (TM 5-3800-205-10-1 or TM
5-3800-205-10-2)
3800-205-10-2)
Grease, GAA (Item 16, WP 0171 00)
REMOVAL
Remove eight screws (5), washers (6), and prop shaft 1,2 3 4
(4) with spiders (3) from machine.
5,6
DISASSEMBLY
If damaged, remove eight screws (1), washers (2), and two spiders (3) from prop shaft (4).
0076 00-1
TM 5-3800-205-23-1
LOWER PROP SHAFT MAINTENANCE - CONTINUED 0076 00
ASSEMBLY
If removed, install two spiders (3) on prop shaft (4) with eight washers (2) and screws (1).
INSTALLATION
1. Install prop shaft (4) with spiders (3) on machine with 1,2 3 4
eight washers (6) and screws (5). Tighten screws to
100 lb-ft (135 Nm).
2. Lubricate two grease fittings with GAA grease (WP
0009 00 and WP 0010 00).
5,6
END OF WORK PACKAGE
0076 00-2
TM 5-3800-205-23-1
FINAL DRIVE MAINTENANCE 0077 00
Removal, Disassembly, Cleaning and Inspection, Assembly, Installation
INITIAL SETUP

Unit Cleaning compound, solvent (Item 6, WP 0171
Tools and Special Tools 00)
Tool kit, general mechanic’s (Item 33, WP 0172 Rag, wiping (Item 31, WP 0171 00)
00)
O-ring
0172 00) Personnel Required
Bolt, guide (Item 3, WP 0172 00)
Two
Bushing, driver set (Item 7, WP 0172 00)
Link, chain, end (Item 19, WP 0172 00) Equipment Condition
Sling, nylon (Item 27, WP 0172 00) Front axle shaft removed (WP 0078 00)
NOTE
0077 00-1
TM 5-3800-205-23-1
FINAL DRIVE MAINTENANCE - CONTINUED 0077 00
REMOVAL
1. Remove two screws (1) and washers (2) from final drive (3) and wheel assembly. Install two guide bolts (4) into final
drive and wheel assembly.
2. Install two chain link ends (5) and attach a nylon sling and suitable lifting device to final drive (3).
WARNING
personnel.
NOTE
Final drive weighs 93 lb (42 kg).
3. Remove 13 remaining screws (1) and washers (2) and use two forcing screws (6) to remove final drive (3) from wheel
assembly.
4. Remove two forcing screws (6).
1,2 3 1,2 4 3 5 6
390-1203
1,2 4
DISASSEMBLY
1. Remove retaining ring (7) from shaft (8).
390-537
8 7
0077 00-2
TM 5-3800-205-23-1
DISASSEMBLY - CONTINUED
2. Remove and discard O-ring (9) from planetary carrier
(11).
8
3. Remove shaft (8) and gear (10) from planetary carrier
(11).
390-538
11 9
10
4. Remove four thrust washers (12 and 13) and two roller 12 13 10
bearings (14) from gear (10).
5. Repeat steps 1 through 4 for other two gears (10).
390-539
14 13 12
WARNING
However, it may be irritating to the eyes and skin. The use of protective gloves and goggles is sug-
gested. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Failure
to do so may result in injury or death to personnel.
1. Clean all removed components with cleaning compound and dry thoroughly.
2. Inspect all parts. Replace worn or damaged parts.
ASSEMBLY
1. Install two roller bearings (14) and four thrust washers (13 and 12) on gear (10).
2. Install gear (10) in planetary carrier (11) with shaft (8).
3. Install new O-ring (9) on planetary carrier (11).
4. Install retaining ring (7) on shaft (8).
5. Repeat steps 1 through 4 for other gears (10).
0077 00-3
TM 5-3800-205-23-1
INSTALLATION
1. Install two chain link ends (5) and attach a nylon sling and suitable lifting device to final drive (3).
WARNING
procedure. Ensure that any lifting device used is in good condition and of suitable lift capacity. Keep
clear of heavy parts supported only by lifting device. Failure to follow this warning may result in death
or injury to personnel.
NOTE
Final drive weighs 93 lb (42 kg).
2. Using guide bolts (4), install final drive (3) on wheel assembly with two washers (2) and screws (1).
3. Install 13 remaining washers (2) and screws (1) on final drive (3). Tighten screws to 96 lb-ft (130 Nm), then tighten
screws an additional 120°.
1,2 3 1,2 4 3 5 6
390-1203
1,2 4
4. Install front axle shaft (WP 0078 00).
END OF WORK PACKAGE
0077 00-4
TM 5-3800-205-23-1
FRONT AXLE SHAFTS REPLACEMENT 0078 00
Removal, Cleaning and Inspection, Installation
INITIAL SETUP

Unit Two

00) 205-10-1 or TM 5-3800-205-10-2)
0172 00) 5-3800-205-10-1 or TM 5-3800-205-10-2)
Materials/Parts
5-3800-205-10-2)
Cleaning compound, solvent (Item 6, WP 0171
00)
3800-205-10-2)
Oil, lubricating (Item 21, 22, or 23, WP 0171 00) Battery disconnect switch in OFF position (TM 5-
O-ring Final drive drained (WP 0010 00)
REMOVAL
NOTE
testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component containing fluids.
1. Remove six bolts (2), washers (3), and cover (4) from 1 2,3
final drive (1).
0078 00-1
TM 5-3800-205-23-1
FRONT AXLE SHAFTS REPLACEMENT - CONTINUED 0078 00
REMOVAL - CONTINUED
2. Remove O-ring (5) from cover (4). Discard O-ring. 4 5
WARNING
NOTE
Axle shaft weighs 53 lb (24 kg).
3. With assistance, remove axle shaft (6) from final drive

1
(1). 6
0078 00-2
TM 5-3800-205-23-1
REMOVAL - CONTINUED
4. Remove retaining ring (7) and gear (8) from axle shaft
7 8 6
(6).
WARNING
However, it may be irritating to the eyes and skin. The use of protective gloves and goggles is sug-
gested. Use in well-ventilated areas. Keep away from open flames and other sources of ignition. Failure
to do so may result in injury or death to personnel.
2. Inspect axle shaft for cracks, bends or breaks.
3. Inspect gear for cracks or chipped or missing teeth.
4. Inspect retaining ring for distortion or other signs of damage.
5. Replace any damaged component.
INSTALLATION
1. Install gear (8) on axle shaft (6) with retaining ring (7).
WARNING
NOTE
Axle shaft weighs 53 lb (24 kg).
2. With assistance, install axle shaft (6) on final drive (1).

3. Coat new O-ring (5) with oil and install to cover (4).
0078 00-3
TM 5-3800-205-23-1
4. Install cover (4) on final drive (1) with six washers
(3) and bolts (2). 1 2,3
4
5. Fill final drive (WP 0009 00 and WP 0010 00).
END OF WORK PACKAGE
0078 00-4
TM 5-3800-205-23-1
FRONT SPINDLE ASSEMBLY MAINTENANCE 0079 00
Removal, Disassembly, Cleaning and Inspection, Assembly, Installation
INITIAL SETUP

Unit Two

Tool kit, general mechanic’s (Item 33, WP 0172 00) Final drive removed (WP 0077 00)
Shop equipment, common no. 1 (Item 24, WP 0172 Hub/brake disc, wheel bearings, and seals removed
00) (WP 0080 00)
Materials/Parts
Cleaning compound, solvent (Item 6, WP 0171 00)
O-ring (2)
REMOVAL
WARNING
NOTE
Spindle weighs 60 lb (27 kg).
Remove eight bolts (1) and spindle (2) from axle 1 2

housing (3).
0079 00-1
TM 5-3800-205-23-1
FRONT SPINDLE ASSEMBLY MAINTENANCE - CONTINUED 0079 00
DISASSEMBLY
1. Remove O-ring (4) and four bolts (5) from spindle
4 2 5
(2). Discard O-ring.
2. Remove retainer (6) from spindle (2).

2 6
3. Remove and discard O-ring (7) from retainer (6). 6 7
0079 00-2
TM 5-3800-205-23-1
FRONT SPINDLE ASSEMBLY MAINTENANCE - CONTINUED 0079 00
WARNING
material. However, it may be irritating to the eyes and skin. The use of protective gloves and goggles is
suggested. Use in well-ventilated areas. Keep away from open flames and other sources of ignition.
Failure to do so may result in injury or death to personnel.
2. Inspect for cracks, breaks, gouges or other damage. Replace if damaged.
ASSEMBLY
1. Install new O-ring (7) on retainer (6).
2. Install retainer (6) on spindle (2).
3. Install four bolts (5) and new O-ring (4) to spindle (2).
INSTALLATION
WARNING
NOTE
Spindle weighs 60 lb (27 kg).
1. Install spindle (2) on axle housing (3) with eight 1 2

bolts (1). Tighten bolts to 95 lb-ft (130 Nm), then
turn bolts another 120°.
3
2. Install hub/brake disc, wheel bearings, and seals (WP 0080 00).
3. Install final drive (WP 0077 00).
END OF WORK PACKAGE
0079 00-3
TM 5-3800-205-23-1
0079 00-4
TM 5-3800-205-23-1
FRONT WHEEL, HUB, BRAKE DISC, AND WHEEL BEARINGS AND SEALS MAINTENANCE 0080 00
Removal, Disassembly, Cleaning and Inspection, Assembly, Installation and Wheel Bearing Adjustment
INITIAL SETUP

Unit Cleaning compound, solvent (Item 6, WP 0171 00)
Oil, lubricating (Item 21, 22 or 23, WP 0171 00)
Tool kit, general mechanic’s (Item 33, WP 0172 00) Seal, duo-cone (2)
Shop equipment, common no. 1 (Item 24, WP 0172 Personnel Required
00)
Two
Bushing, driver set (Item 6, WP 0172 00)
Equipment Condition
Braket, link (Item 4, WP 0172 00) Brake caliper removed (WP 0087 00)
Sling, nylon (Item 27, WP 0172 00) Final drive removed (WP 0077 00)
REMOVAL
WARNING
NOTE
Ring gear weighs 45 lb (20 kg).
1. Remove retaining ring (3) from ring gear (1). With 1 2

assistance, remove ring gear from hub (2).
0080 00-1
TM 5-3800-205-23-1
FRONT WHEEL, HUB, BRAKE DISC, AND WHEEL BEARINGS AND SEALS
MAINTENANCE - CONTINUED 0080 00
REMOVAL - CONTINUED
2. Attach bearing link, nylon strap, and a suitable over- 4 5 2
head lifting device to wheel (4). Take up slack in
sling.
3. Remove eight bolts (5), retainer plate (6), and wheel
bearing adjustment shims from spindle.
WARNING
procedure. Ensure that any lifting device used is in good condition and of suitable load capacity. Keep
clear of heavy parts supported only by lifting device. Failure to follow this warning may cause injury or
death.
NOTE
Wheel weighs 183 lb (83 kg).
4. Remove hub (2) from wheel (4). Remove wheel 2 4

from machine. Remove sling and bearing link from
wheel.
0080 00-2
TM 5-3800-205-23-1
DISASSEMBLY
1. Using puller, remove roller bearing (7) from hub
(2).
2. Remove duo-cone seal (8) and roller bearing (9) 8 9

from spindle (10). Discard seal.
10
3. Remove duo-cone seal (11) from wheel (4). Discard 11 4

seal.
4. Remove 24 bolts, washers, and brake disc from
wheel (4).
0080 00-3
TM 5-3800-205-23-1
WARNING
material. However, it may be irritating to the eyes and skin. Use protective gloves and goggles. Use in well-
ventilated areas. Keep away from open flames and other sources of ignition. Failure to do so may result in
2. Inspect for cracks, breaks, chips, excessive scoring or other damage. Replace any damaged component.
3. Inspect bushing inside hub for damage. If damaged, remove and replace bushing.
4. Inspect bearing cups in wheel for damage. Remove and replace bearing cups if damaged.
ASSEMBLY
1. Install brake disc to wheel (4) with 24 washers and 11 4
bolts.
2. Using cone installer, install new duo-cone seal (11)
to wheel (4).
0080 00-4
TM 5-3800-205-23-1
ASSEMBLY - CONTINUED
3. Coat with oil and install roller bearing (9) on spindle 8
(10).
4. Using cone installer, install new duo-cone seal (8)
on spindle (10).
9 10
WARNING
Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.
5. Heat roller bearing (7) to 275°F (135°C), coat with 7

oil, and install roller bearing on hub (2).
0080 00-5
TM 5-3800-205-23-1
INSTALLATION AND WHEEL BEARING ADJUSTMENT
WARNING
procedure. Ensure that any lifting device used is in good condition and of suitable load capacity. Keep
clear of heavy parts supported only by lifting device. Failure to follow this warning may cause injury or
death.
NOTE
Wheel weighs 183 lb (83 kg).
1. Attach bearing link and nylon sling to wheel (4). 2 4

Use a suitable overhead lift to install wheel.
2. Install hub (2) inside wheel (4).
390-898
NOTE
Assistance from DS Maintenance is required to perform measurements for wheel bearing adjustment.
3. Adjust wheel bearings:
a. Use an outside micrometer to measure thickness of retainer plate (6) at three small holes in plate. Calculate
average thickness and record.
NOTE
Install three bolts in bolt holes next to three small holes in retainer plate.
b. Install retainer plate (6) to spindle with three bolts (5). Do NOT install shims. Do NOT tighten bolts.
c. Rotate wheel (4) and tighten three bolts (5) to 74 lb-ft (100 Nm) in order to seat parts.
d. Loosen three bolts (5).
e. Tighten three bolts (5) to 18 lb-ft (25 Nm). Rotate wheel several revolutions and retighten bolts to 18 lb-ft (25
Nm). Repeat wheel rotation and bolt tightening until bolts hold torque.
f. Use a depth micrometer to measure depth of three small hoses in retainer plate. Calculate average depth and
record.
0080 00-6
TM 5-3800-205-23-1
INSTALLATION AND WHEEL BEARING ADJUSTMENT - CONTINUED

g. Calculate difference between measurements in step a and step f. Difference is gap between end of spindle and
retainer plate (6).
h. Remove three bolts (5) and retainer plate (6) 4 5 2
from spindle.
i. Assemble quantity of shims, so that shim pack
thickness is equal to measurement in step g plus
0.203 mm (0.008 in.).
j. Install shims, retainer plate (6) and eight bolts
(5). Tighten bolts to 44 lb-ft (60 Nm), then
tighten an additional 120°.
6
WARNING
NOTE
Ring gear weighs 45 lb (20 kg).
4. With assistance, install ring gear (1) to hub (2) with 1 2

retaining ring (3).
3 390-896
5. Install brake caliper (WP 0087 00).

6. Install final drive (WP 0077 00).
END OF WORK PACKAGE
0080 00-7
TM 5-3800-205-23-1
0080 00-8
TM 5-3800-205-23-1
DIFFERENTIAL LOCK CONTROL VALVE MAINTENANCE 0081 00
Removal, Installation, Adjustment
INITIAL SETUP

205-10-1 or TM 5-3800-205-10-2)
5-3800-205-10-2)
Materials/Parts
Tape, antiseizing (Item 40, WP 0171 00) Battery disconnect switch in OFF position (TM 5-
3800-205-10-1 or TM 5-3800-205-10-2)
Personnel Required
Air tanks drained (TM 5-3800-205-10-1 or TM 5-
Two 3800-205-10-2)
WARNING
• Do NOT disconnect any air system lines or fittings unless vehicle engine is shut down and air system
pressure is relieved. Failure to follow this warning could result in serious injury to personnel.
• Always wear eye protection when disconnecting air lines. Residual air will be expelled. Failure to fol-
low this warning may result in serious eye injury.
0081 00-1
TM 5-3800-205-23-1
DIFFERENTIAL LOCK CONTROL VALVE MAINTENANCE - CONTINUED 0081 00
REMOVAL
1. Tag and disconnect inlet air hose (2) and outlet air hose (3) from differential lock control valve (1), located under cab
floor.
2. Remove two bolts (5) and foot rest (4). 4
0081 00-2
TM 5-3800-205-23-1
REMOVAL - CONTINUED
NOTE
It may be necessary to move or remove floor padding for access to differential locknut.
3. Loosen locknut (6).
4. With assistance under tractor, remove locknut (6) and
differential lock control valve (1) from cab floor.
INSTALLATION
1. With assistance under tractor, install differential lock control valve (1) on cab floor with locknut (6).
2. Install foot rest (4) on cab floor with two bolts (5).
NOTE
Apply antiseize tape to clean threads of fittings before connections are made.
3. Connect outlet air hose (3) and inlet air hose (2) to differential lock control valve (1).
0081 00-3
TM 5-3800-205-23-1
ADJUSTMENT
1. Measure distance between top of bolt (8) (located on bottom of pedal (7)) and bottom of pedal (Measurement A). Dis-
tance should be approximately 0.75 in. (19.0 mm). Adjust bolt as required.
0.75 in.
0.16 in. (19.0 mm)
(4.1 mm)
NOTE
Ensure that bolt located on bottom of pedal contacts floor before stroke of stem in differential lock control
valve bottoms out.
2. With pedal (7) depressed, measure distance of valve stem movement (Measurement B). Measurement should be 0.16 in.
(4.1 mm). Adjust bolt (8) as required.
END OF WORK PACKAGE
0081 00-4
TM 5-3800-205-23-1
PARKING BRAKE ASSEMBLY MAINTENANCE 0082 00
Removal, Cleaning and Inspection, Installation, Adjustment
INITIAL SETUP

5-3800-205-10-1 or TM 5-3800-205-10-2)
5-3800-205-10-2)
00)
Materials/Parts
3800-205-10-2)
Pin, cotter
205-10-1 or TM 5-3800-205-10-2) 3800-205-10-2)
REMOVAL
1. Remove cotter pin (7) and clevis pin (8) from yoke rod end (9). Discard cotter pin.
2. Remove eight bolts (1), washers, and brake drum (3) from flange (2).
3. Remove bolt (5), washer (6), and flange (2) from parking brake assembly (4).
1 2 3 4 2 5
390-435
9 8 7 6
0082 00-1
TM 5-3800-205-23-1
PARKING BRAKE ASSEMBLY MAINTENANCE - CONTINUED 0082 00
REMOVAL - CONTINUED
4. Remove four bolts (10) and parking brake assembly 10 4

(4) from transfer case.

1. Clean all components of parking brake group.
NOTE
If linings are worn down to rivet heads, brakeshoes are not serviceable.
2. Inspect and replace any item found to be worn or damaged.

INSTALLATION
1. Install parking brake assembly (4) on transfer case with four bolts (10).
2. Install flange (2) on parking brake assembly (4) with washer (6) and bolt (5).
3. Install brakedrum (3) on flange (2) with eight washers and bolts (1).
4. Install yoke rod end (9) with clevis pin (8) and new cotter pin (7).
4 2 5 1 2 3
9 8
6 7
0082 00-2
TM 5-3800-205-23-1
PARKING BRAKE ASSEMBLY MAINTENANCE - CONTINUED 0082 00
ADJUSTMENT
NOTE
• Parking brake is correctly adjusted if machine cannot be moved in second speed forward with engine at
high idle.
• Brakedrum must be free to rotate when parking brake is released.
1. Place battery disconnect swtich in ON position (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).
WARNING
2. Start engine (TM 5-3800-205-10-1 or TM 5-3800-205-10-2). Allow air pressure to reach operating pressure.
3. Move parking brake control knob to OFF position. Stop engine (TM 5-3800-205-10-1 or TM 5-3800-205-10-2).
4. Remove cotter pin (7) and clevis pin (8).
5. Push end of lever (12) away from parking brake actuator (15) until brake linings (11) come into contact with brakedrum
(3).
6. Loosen locknut (13). Rotate yoke rod end (9) on threaded rod (14) until holes in yoke rod end and in lever (12) are
aligned. Rotate rod end by one turn toward parking brake actuator (15). Insert clevis pin (8) and cotter pin (7). Tighten
locknut (13).
11 3
15 14 13 9 7,8 12
END OF WORK PACKAGE
0082 00-3
TM 5-3800-205-23-1
This Page Intentionally Left Blank
0082 00-4
TM 5-3800-205-23-1
AIR COMPRESSOR GOVERNOR AND AIR COMPRESSOR MAINTENANCE 0083 00
Air Compressor Governor: Removal, Installation

Air Compressor: Removal, Installation
Air Strainer: Removal, Cleaning and Inspection, Installation
INITIAL SETUP

Unit WP 0009 00
Personnel Required
00) Two
Sling, nylon (Item 27, WP 0172 00)
Equipment Condition
Materials/Parts
Front and center guard plates removed (WP 0100
Antifreeze (Item 2 or 3, WP 0171 00)
00)
Cleaning compound, solvent (Item 6, WP 0171 Air tanks drained (TM 5-3800-205-10-1 or TM 5-
00) 3800-205-10-2)
Sealant, pipe (Item 34, WP 0171 00) Engine access door open (TM 5-3800-205-10-1 or
Tag, marker (Item 39, WP 0171 00) TM 5-3800-205-10-2)
Gasket (3) Coolant drained (WP 0010 00)
WARNING
• Do NOT disconnect any air lines or fittings unless engine is shut down and air system pressure is
• Always wear eye protection when disconnecting air lines. Residual air will be expelled. Failure to fol-
low this warning may result in serious eye injury.
CAUTION
Cap all hoses and tubes to prevent contamination of air system.
NOTE
Tag all hoses and tubes to aid in installation.
0083 00-1
TM 5-3800-205-23-1
AIR COMPRESSOR GOVERNOR AND AIR COMPRESSOR MAINTENANCE - CONTINUED 0083 00
AIR COMPRESSOR GOVERNOR REMOVAL
1. Remove vent valve (4) from air compressor governor (7).
2. Loosen collar (12) of adapter (13) and disconnect hose (1) from adapter.
3. Disconnect hose (2) from adapter (3).
4. Remove two long bolts (5), washers (6), and governor (7) from plate (11).
5. Remove two adapters (3 and 13) from governor (7).
6. If damaged, remove two bolts (9), washers (10), and plate (11) from fan drive (8).
1 2,3
12,13
11
4
9,10
5,6
AIR COMPRESSOR GOVERNOR INSTALLATION
1. If removed, install plate (11) to fan drive (8) with two washers (10) and bolts (9).
2. Apply a thin coat of pipe sealing compound to pipe threads of two adapters (3 and 13) and install adapters to governor
(7).
3. Install governor (7) to plate (11) with two washers (6) and long bolts (5).
4. Connect hose (2) to adapter (3).
5. Connect hose (1) to adapter (13) and tighten collar (12).
6. Apply a thin coat of pipe sealing compound to pipe threads of vent valve (4) and install vent valve to governor (7).
0083 00-2
TM 5-3800-205-23-1
AIR COMPRESSOR GOVERNOR AND AIR COMPRESSOR MAINTENANCE - CONTINUED 0083 00
AIR COMPRESSOR REMOVAL

1. Disconnect two hoses from air compressor governor (Refer to steps 1 through 3 of Air Compressor Governor Removal).
2. Remove bolt (19), washer (20) and two hose clips (18) from air compressor (21).
3. Disconnect hose (15) from elbow (14) on air compressor (21).
4. Disconnect tube (17) from elbow (16).
15 16 17
14
9
18
19,20
390-1765
21
0083 00-3

TM 5-3800-205-23-1 Part 1 Model 613CS and Model 613CWD

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TM 5-3800-205-23-1

FIELD MAINTENANCE MANUAL

DISTRIBUTOR, WATER, TANK TYPE,

TRACTOR AND COMMON COMPONENTS

Approved for public release; distribution is unlimited.

HEADQUARTERS, DEPARTMENT OF THE ARMY

This page is blank.

POISON - skull and crossbones shows material is poinsonous or is a danger to life.

FOR INFORMATION ON FIRST AID, REFER TO FM 4-25.11.

CARBON MONOXIDE (EXHAUST GASES) CAN KILL!

The Best Defense Against Carbon Monoxide Poisoning Is Good Ventilation!

ETHER COLD START SYSTEM

HAZARDOUS WASTE DISPOSAL

To order this NBC decal use:

PREPARATION FOR TRANSPORT

PRESSURIZED COOLING SYSTEM

SOLVENT CLEANING COMPOUND

LIST OF EFFECTIVE PAGES/WORK PACKAGES

Date of issue for original manual is:

Original 15 JULY 2005

* Zero in this column indicates an original page or work package.

This Page Intentionally Left Blank.

TECHNICAL MANUAL HEADQUARTERS

FIELD MAINTENANCE MANUAL

(INCLUDES UNIT AND DIRECT SUPPORT MAINTENANCE)

DISTRIBUTOR, WATER, TANK TYPE,

TRACTOR and COMMON COMPONENTS

REPORTING ERRORS and RECOMMENDING IMPROVEMENTS

CHAPTER 1 INTRODUCTORY INFORMATION WITH THEORY OF OPERATION

WP 0001 00 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0001 00-1

Table of Contents - Continued

CHAPTER 2 TROUBLESHOOTING PROCEDURES

WP 0004 00 Troubleshooting Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0004 00-1

CHAPTER 3 UNIT MAINTENANCE PROCEDURES

WP 0008 00 Service Upon Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0008 00-1

CHAPTER 4 UNIT LEVEL TRACTOR MAINTENANCE

Table of Contents - Continued

Electrical System - Continued

Table of Contents - Continued

Table of Contents - Continued

CHAPTER 5 DIRECT SUPPORT LEVEL TRACTOR MAINTENANCE

Table of Contents - Continued

Propeller and Propeller Shafts

CHAPTER 6 COMPONENTS OF END ITEM (COEI) MAINTENANCE

WP 0163 00 Container Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0163 00-1

CHAPTER 7 SUPPORTING INFORMATION

WP 0168 00 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0168 00-1

Table of Contents - Continued

CHAPTER 1 UNIT LEVEL SCRAPER MAINTENANCE

Table of Contents - Continued

CHAPTER 2 DIRECT SUPPORT LEVEL SCRAPER MAINTENANCE

CHAPTER 3 SUPPORTING INFORMATION

WP 0044 00 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0044 00-1

Table of Contents - Continued

CHAPTER 1 UNIT LEVEL WATER DISTRIBUTOR MAINTENANCE

Table of Contents - Continued

Water Distributor System

CHAPTER 2 DIRECT SUPPORT LEVEL WATER DISTRIBUTOR MAINTENANCE

CHAPTER 3 SUPPORTING INFORMATION

WP 0041 00 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0041 00-1

HOW TO USE THIS MANUAL

This Page Intentionally Left Blank.